Typical Maintenance Manual

SHORT DESCRIPTION OF CHIMNEY

The chimney basically consists of a concrete structure (windshield) with two number internal
flues in steel to conduct waste gas from the boilers into the atmosphere. It is fitted with all
necessary accessories to make it into a complete and functioning piece of equipment.

WARNING
OVERVIEW

In any work concerning the operation, conversion or adjustment of the structure and its safety
devices or any work related to maintenance, inspection and repair, always observe the start-up
and shut-down procedures set out in the operating instructions and the information on
maintenance work.

BEFORE YOU OPERATE, MAINTAIN OR IN

ANY OTHER WAY OPERATE THIS UNIT:
READ and STUDY this manual. KNOW how to
safely use the unit’s controls and what you must
do for safe maintenance.

The structure has been built in accordance with state-of-the-art standards and the recognised
safety rules.

ALWAYS wear or use the proper safety items required for your personal protection.
For reasons of security, long hair must be tied back or otherwise secured, garments must be
close, fitting and no jewellery - such as rings- may be worn. Injury may result from being caught
up in the machinery or from rings catching on moving parts.

If you have ANY QUESTIONS about the safe use or maintenance of this unit, ASK YOUR
SUPERVISOR. NEVER GUESS, ALWAYS CHECK.

Never make any modifications, additions or conversions that might affect safety without the
supplier’s approval. This also applies to the installation and adjustment of safety devices as well
as to welding work on load-bearing elements.

LOOK FOR THESE SYMBOLS WHICH POINT OUR ITEMS OF EXTREME IMPORTANCE TO
YOU AND YOUR CO-WORKERS’ SAFETY, READ AND UNDERSTAND THOROUGHLY,
READ THE DANGERS, WARNINGS, CAUTIONS AND NOTES AND FOLLOW THE
INSTRUCTIONS.

1
 ! “DANGER” ! “WARNING”
DANGER is used to indicate the presence of an WARNING is used to indicate the presence of a
immediate hazard which WILL result in hazard or unsafe practice which could result in
SEVERE personal injury or death. SEVERE personal injury or death.

! “CAUTION”
CAUTION is used to indicate the presence of a
hazard or unsafe practice which could result in
MINOR personal injury or product or property
damage.
! “NOTE”
NOTE is used to indicate installation, operation, or
maintenance information which is important but not
hazard related.

“WARNING”
This manual contains instructions for
installation, operation and maintenance
of your chimney that has been designed
to provide safe and reliable service.
The instructions in this manual are
intended for personnel with a general
training in operation and maintenance
of chimneys.
SAFETY LABELS

On the unit are fitted the following labels (where applicable):

Warning:
do not attempt to lift the Warning:
compressor package by electrical shock risk.
the enclosure. Damage
to equipment and
personnel could result.

Warning:
prohibited to walk on Do not breathe the
the canopy roof. compressed air from
this unit.

Indication where the

instruction book is Warning:
located. hot surface.

Do not remove the

operating and Do not operate the
maintenance manual machine without the
from this compressor. guard being

Read the instruction

book before the Warning:
operation or air/gas flow or air
maintenance of this discharge
compressor is
undertaken.

Oil fill
Lifting point
 Warning: Direction of rotation of
Automatic start the compressor gear
compressor

Do not stand on any

service valve or other
parts of the pressure
system

SAFETY

Note that the maximum design operating temperature of the flue gas is high enough that if
external insulation is removed for inspection then the metal surface temperature could exceed
250°C.

Note while assessing or inspecting the top of the chimney, that most atmospheric variations
may occasionally cause high temperature corrosive gases to downwash around the top of the
chimney.

All temporary platforms, scaffolds, hoists and access arrangements should be designed and
installed by experienced and competent persons. These items should be specifically designed
for the precise duty, should be in accordance with relevant regulations, and should be carefully
inspected before and during use.

Because of the proximity of hot and corrosive gases it is essential that when personnel enter the
chimney, even for routine inspections, that they do so only after the issue of a formal written
permit to be signed by the Station Supervisor, and that the station operating personnel are also
formally aware that inspection is taking place.

At least two people should go into the chimney, so that, in the event of an accident, assistance
can be called for.
 0. SECTION INDEX

PLANT DESCRIPTION

1.0 INTRODUCTION

1.0. GENERAL DESIGN PARAMETERS

1.0. Design Codes.

1.0. Design Parameters.

2.2.1. Wind Loads.

2.2.2. Earthquake Loads

1.1.2. Platform Live Loads

1.1.2. Foundation.
1.0 INTRODUCTION

All levels and heights given are relative to top of foundation level of EL +0.0m, which is
equivalent to EL + 452.0m.above Sea Level.
The chimney windshield and flues are shown in outline on the General Arrangement drawing.
The chimney construction comprises of a reinforced concrete windshield 201.8m. in height
and tapers from a base external diameter of 15.60m to a top external diameter of 13.670m.
The windshield houses on the East-West centre line 2no. steel flues, each having a constant
internal diameter of 5.160m. On the East and West elevation are sited 2no. inlet Breech
ducts having a clear opening size of 7.600m in height and 3.800m in width. The liner
assemblies are supported and suspended from the top of the roof slab at EL+199.80m. Each
liner assembly incorporates 20no. high tensile steel hanger rods of 24mm. in diameter.
Additional hanger support rods to both liner assemblies are provided at the Breech ducts and
their location is at the top of the 16.000m.floor. Fitted to the flue liners are lateral support
member and these are located at the 16.00m. ; 19.000m. ; 108.000m levels and at the
underside of the roof slab.
The flue is fed by means of the two stiffened-steel plate breeching ducts located on the East
and West elevations. Each flue assembly, including the inlet ducts are fully insulated to limit
the dissipation of the flue gas temperatures, thus maintaining that the surface temperature of
the cladding material shall not exceed 57 o C. The insulation applied to the liners consists of
Fibremesh-350 Rockwool flexible fibre mattress reinforced with a galvanised wire mesh and
an outer aluminised covering. The exposed sections of the liner at roof level and at the inlet
Breech ducts sited on the East and West elevations are further protected metal cladding to
protect the insulation from weather and mechanical damage.
Fitted inside the windshield is a staggered ladder complete with safety hoops and rest
platforms set at approximately 6.000m.intervals, a permanent personnel lift, access and roller
shutter doors, ventilation louvres at the base and at locations directly below the roof slab.
There are three internal platforms, one constructed in concrete and the remaining two in
structural steel. Gas sampling ports are accessible from the 105.0m floor.
The windshield also includes a full lightning protection system, permanent lighting and power
circuits complete with main distribution boards and a grounding system.
The chimney was designed and constructed generally by *************. The design also
included the foundation for the windshield and included all below grade grounding and
installation of electrical conduits and floor drainage.
The contract construction documents, such as drawings and general design parameters are
in the following Section 2 and 3, are listed

2.0. GENERAL DESIGN PARAMETERS

The 201m.m x 5.160m twin flue reinforced concrete chimney was designed under the
following brief working and environmental parameters: -
2.1. Design Codes.
• Windshield Design Code ACI 307 – 98. Standard Practice for the Design and
Construction.
• Liner Design Code CICIND Model Code for Concrete Chimneys Part C Steel Liners-
1995.

The design also complies with the following Australian Standards.

AS. 1170.1. 1989 Loadings
AS. 1170.2. 1989 Wind Loads
AS. 1170.4. 1993 Earthquake Loads
AS. 3600. 1994 Concrete Structures
AS. 4100. 1998 Steel Structures
AS. 1657. 1992 Fixed Ladders and Walkways

1.0. Design Parameters.

2.2.1. Wind Loads.

Vu-50 m/sec.
Vp-41 m/sec.

Terrain Category 2

2.2.2. Earthquake Loads.

Acceleration coefficient a =. 07
Site Factor S = 1
Importance Factor 1- 1.25
Structure Type = 111

1.1.2. Platform Live Loads.

Design Live Load = 4kPa

1.1.2. Foundation.

Foundation Bearing Pressure = 660 kPa

 SUB SECTION 1.2
CONSTRUCTION
1.0 Windshield and Roof

2.0 Foundation

3.0 Flue

4.0 Expansion Joint (Fabric material).

5.0 Elastomeric Bearings

6.0 High Tensile Steel Support Rods at Upper section of the Liner.

7.0 Inlet Ducts

1.0 Insulation

2.0 Permanent Ladder Access.

3.0 Permanent Passenger Lift System.

4.0 Temporary Construction Opening

5.0 Internal Platforms.

6.0 Internal Personnel Lift

7.0 Access Door into the Windshield.

8.0 Gas Monitoring/Sampling Ports.

9.0 Ventilation Louvre Panels.

10.0 Drainage.

11.0 Internal Lighting and Power.

12.0 Lightning Protection System.

13.0 Aircraft warning Light installation (fitted externally).

 CHIMNEY

1.0 Windshield and Roof

The windshield is constructed from concrete with 28-day cylinder strength of 30Mpa to
AS3600 - 1994 and reinforcement to AS1302 grade 400Y(minimum yield strength 400MPa)
with 50mm as the minimum concrete cover. It stands 201.80m high and tapers from a base
external diameter of 15.60m.(at EL – 0.80m) to a top external diameter of 13.670m. The
windshield wall thickness varies over the height as stated in Table 4.0; extract from the
dimension shown on the reinforcement drawings.

Table 1 WINDSHIELD GENERAL ARRANGEMENT DETAILS

WINDSHIELD Site Datum External Diameter, Wall Thickness, (mm)

(m)

Top of Parapet EL +201.0m. 13.670m. 255

EL +195.0m 13.670m. 255
EL +150.0m 13.670m. 255
EL +105.0m. 13.704m. 272
EL +95.0m 13.726m. 283
EL +17.0m 15.195m. 449
Ground Level EL +0.0m 15.595.0m. 549
Top of Foundation EL –0.80m.0. 15.600m. 550

DUREBILD STE Glass Flake Reinforced Epoxy Coating is applied to the top 10.00m of the
outside surface of the reinforced concrete windshield, the inside surface of the parapet wall and
to the upper surfaces of the concrete roof. The coating membrane is supplied by ORICA
Protective Coatings and the product, is manufactured by Dulux. The Product name is:- 775
LINE DUREBILD STE GF PART A
A Polysulphide Sealant is used at the roof level to seal between the concrete surface and
mechanical fixtures fastened to roof assembly.

1.0 Foundation

The foundation has been designed and constructed by *************. Refer to drawing
numbers ****** to *******.

1
3.0 Flue

The 207.00m high steel flue has a constant internal diameter of 5.160m from EL +14.70m to
EL + 206.00m. From 206.00m to 210.00m the internal diameter increases from 5.160m to
5.670m. The flue is designed for in-service gas temperatures ranging from a minimum of
82.2°C to a normal maximum operational temperature of 137.8°C, and a maximum excursion
of 358°C for 30 minutes. The thickness of the flue steel liner remains constant at 6mm. The
upper part of the flue is suspended at EL +199.80m from the roof and laterally supported at
4No. locations within the concrete windshield. The lower section comprising of the inlet ducts
is supported from hanger rods located at the 16.00m floor and structural support beams
mounted to the concrete upstand.
The external surfaces of the flue liner, together with all other items welded to the flue are
uncoated. There are no finish requirements to the internal surfaces of the steel liner
assemblies.

Table 2 FLUE GENERAL ARRANGEMENT DETAILS

FLUE Site Datum Internal Diameter, (m) Thickness, (mm)

Top of Liner EL +210.00m 5.670m 6mm. Grade 316
3rd. Floor Level EL +195.00m 5.160m. 6mm. Carbon Steel
2nd. Floor Level EL +105.00m. 5.160m. 6mml. Carbon Steel
1st.Floor Level EL +16.00m 5.160m. 6mm. Carbon Steel

4.0 Expansion Joint (Fabric material).

The expansion joint separates the upper section of the liner cans from the lower section of
the Breeching duct assembly. This is basically a single bellows type arrangement and was
designed to accommodate the expansion of the liner. The monolithic expansion skirt is bolted
to the upper and lower flanges of liner cans.

5.0 Elastomeric Bearings

Elastomeric bearings are located on the top surfaces of the concrete corbels that support the
roof slab.
Elastomeric bearing pads are also fitted at 4no. locations at the support members at the
16.0m floor level
Elastomeric bearing pads are located at the bearing ends of the main support beam
members for the floors at 105.0m and 195.0m
The Elastomeric Bearing pads were manufactured and supplied by ***************.

6.0 High Tensile Steel Support Rods at Upper section of the Liner.

Each flue is suspended at EL +199.80m.(top of roof slab) by twenty number 24mm diameter
galvanised high tensile steel rods. The rods are seated on galvanised steel washers and
contained within stainless steel boxes, which are filled with acid resisting grease. The rods
are threaded at each end to metric M24, the roof connection is made up of the following
components; galvanised flat washer size 120x120x20 thick- M24 full nut – M24 lock nut and
plain washer. At the liner lifting and support ring the connection components consist of
galvanised washers and spacing plates, the 24mm diameter support rods are fully insulated
from the effects of direct temperature transference from the liner
 The assembled supporting rods at the liner support ring are fully insulated by the use of the
mineral rockwool insulation blanket.

7.0 Inlet Ducts

The flue gas ducts, which approach the chimney, are provided under a separate contract.
They connect to the two inlet ducts, which are supported an insulated beam assembly. The
support system is fastened to the cill of the individual concrete breech openings on the cill of
the windshield openings
The inlet ducts, which form an integral part of the flue liner assembly are fabricated from
6mm steel plate and externally insulated with a 50mm thick Fibremesh-350 Rockwool
mattress.
Lapping steel sheets are provided between the external cladding and the adjacent concrete
windshield to keep the effects of weather away from the annulus seal and the bearings.

8.0 Insulation

The Bradford Fibremesh-350 is a lightweight thermal insulation. The insulation fibre has a
minimum density of 48 kg/m3, and a maximum coefficient of thermal conductivity of 0.048
W/m°K at a mean temperature of 77°C. This Fibremesh-350 is backed with a galvanised
hexagonal wire mesh. The projection of the liner cans above the roof level are covered by a
100mm layer of mineral wool insulation and an outer protection of 1mm thick stainless steel
cladding as a protection against weather. The insulation ensures that the flue gas
temperature drops is limited to 5°C under the proposed working gas temperatures.
The flue, ducts, and lateral supports exposed to the chimney interspace are insulated with
50mm thick mineral wool.
Insulation of 50mm in thickness is installed in a single layer and held in position with
galvanised steel bands. The method for applying the 100mm thick layer of insulation is made
up of two layers and held in position with galvanised steel bands.

9.0 Permanent Ladder Access.

Access is available over the full height of the chimney via an internal staggered ladder. The
ladder assembly is fitted with a safety cage and rest platforms at 6.0m approximate levels.
The ladder is fixed to the inside surface of the windshield and starts from ground level EL+
0.00m and climbs to afford access to all the internal floor levels and the roof at EL +
199.80m.

10.0 Permanent Passenger Lift System.

The personnel lift system is manufactured and supplied by Alimak Australia. The system
operates on a rack and pinion drive principle. The lift operates from a ground level landing
station and affords access to the 16.0m; 105.0m and the 195.0m floor levels.

11.0 Temporary Construction Opening

Temporary access is made available during construction at ground level through a 5.7m x
10.3m opening in the windshield. The construction opening is situated on the North face of
the windshield.
At completion of all works associated with the flue liners, the aperture is blocked off with steel
supports and cladding material. The final construction includes an opening for a roller shutter
door, an access door and ventilation louvers.
12.0 Internal Platforms.

There are 3no internal floors that are designed within the windshield. The first floor occurs at
level 16.0m, this floor is constructed as a pre-cast reinforced concrete unit.
The second and third floor at levels 105.0m and 195.0m respectively are designed and
constructed from steel.
Access to all the floors are by means of the permanent Alimak passenger lift system or in an
emergency or power failure via the permanent ladder arrangement.

13.0 Internal Personnel Lift

The passenger lift system is manufactured and supplied by Alimak. The drive mechanism is
a rack and pinion system. The lift travels from a bottom landing station at 1.295m above
ground level. The lift has landing platforms at the 16.0m, 105.0m and 95.0m floors. It travels
at 0.66m/s, and is designed to stop automatically at these landing locations. The Alimak lift’s
mast tower is fixed to the South West corner of the windshield.
Full details on the method of assembly of the components associated with the mast tower
and the total installation of the lift system are described in the Alimak manual.

14.0 Access Door into the Windshield.

Permanent access into the windshield is through the access door which is built into the
construction block-out panel assembly.
Permanent access into the chimney interspace is provided through personnel doors in the
windshield at ground level EL +10.0m, the base of the flue EL +26.534m, the base of the
expansion joint EL +34.332m, and at the flue gas monitoring platform EL +94.616m on the
north face of the chimney, and on to internal platforms at EL 149.5m
No other access is provided into the interspace.

15.0 Gas Monitoring/Sampling Ports.

Gas monitoring ports are installed at the two flue liner cans, these ports are accessible from
the 105.0m floor.

Four 0.75m x 0.75m galvanised Test Probe Hatches are located at 90° about the
circumference of the windshield at EL +95.6m to assist in monitoring of the flue gases from
the EL +94.616m platform. A 6mm galvanised steel plate covers each hatch.

16.0 Ventilation Louvre Panels.

Ventilation louvre assemblies are fitted at the location of the 195.0m floor level and nits occur
below the flue breeching ducts o the East and West side of the windshield. Additional
ventilation louvers are incorporated in the design of the construction block-out panel.
The 6no. ventilation louvers units fitted at El + 196.70m.are manufactured from grade 316
stainless steel and fitted with a bird mesh. The louvre units fitted at the bottom of the
windshield are manufactured from Zinc Aluminium sheets.

17.0 Drainage.

The roof is drained by the inclusion of 6no. 100mm diameter PVC pipes and they have been
cast into the parapet wall. The invert levels are set with the inner face level with the top of the
roof slab and a slight fall towards the external face of the windshield.
At ground level, there are two locations on the South side that are drainage outlets. These
are the discharge points for draining surface water from the internal ground floor to an
underground drainage system by others.

18.0 Internal Lighting and Power.

 The ground floor is lit by 10no. 58watt Fluorescent light fittings fixed to the inside face of the
windshield at approximately 2.7m above ground level.
6no. 58watt Fluorescent light fittings and power points are installed and included in the
circuitry for the 16.0m.floor.
Lighting and power points are also fitted at the 105.0m.and 195.0m. floors.
Running along side of the permanent ladder arrangement are 58watt Fluorescent light
fittings. All light fittings are mounted on Unistrut members.
The floor levels have power sockets, primarily intended for use of small tools or extension
leads.
The electrical supply cables are installed in a cable ladder arrangement and fixed to the
inside face of the structure adjacent to the permanent ladder and rest platforms.

19.0 Lightning Protection System.

The lightning protection system is installed in accordance with AS 1768 – 1991 and in
accordance with the requirements of the contract specification and drawing no. TN741186.
The system comprises of 6no. down conductors cast into the concrete shell. The down
conductors comprise of 16mm.diameter rods continuously welded and at the intersection of
every floor level, coronal bands consisting of 50mm wide x 5mm thick galvanised mild steel
strip forming a complete ring is bonded to every down conductor.
At 1.50m above ground level 6no. test clamps are fitted to the external face of the
windshield. The test clamps are connected to the ground earthing system by the utilisation of
a 25mm wide x 3mm thick copper tape The ground earth system comprises of 8no. earth
straps of size 50mm.wide x 5mm. thick galvanised mild steel strip set into positions in a
150mm. diameter bored hole to a depth of 30.0m. The bored hole is filled with Bentonite. The
8no. earth straps are connected to a ring main circuit, consisting of 50mm wide x 5m thick
galvanised mild steel strip. At ground level 8no.earth pits are installed, connected to the earth
rods fitted inside the earth pits are copper tape connections from the respective test clamps.
All metal components including the liner can assembly is bonded to the Lightning Protection
system either by copper cables or in situations at the uppermost floor level and the roof slab
by lead covered copper tape.

20.0 Aircraft warning Light installation (fitted externally).

This installation comprises of three towers equi-spaced and positioned at a radius

approximately 45.0m from the centre point of the structure. Three units of Metal Halide Sill
Flood Lights by Versalux are fitted to each tower. The light fittings incorporate steady-burning
lamps, which operate on 230 volts at 50 Hertz. The Aircraft Warning Lights illuminate the
outside profile of the reinforced concrete structure. The lights are set to operate via a
photoelectric cell included in its circuitry.
The Aircraft Warning lights are controlled through their own control panels and supply fed
from the main distribution boards. The supply cables are to the individual tower assemblies
are installed in PVC conduit buried in the ground. The supply cables to the Aircraft Warning
Lights are provided by the Client.
 2. SECTION INDEX

OPERATING PROCEDURES
1.0 OPERATION
1.0 GAS CONDITIONS
2.1 OPERATION

It must be borne in mind that this chimney is as much a piece of operating plant as is any
other on the power station, even though it may have few or no moving parts. Although this
point may make it seem as if there is little that can go wrong and although the very
appearance of the structure lends credence to the assumption of invincibility, this applies
mostly to the concrete structure, which is indeed structurally robust. Those parts carrying the
flue gases, subjected as they often are to extremes of temperature and chemical attack are
of a more fragile nature and should be treated as such.
It is thus most important that the plant and in particular the chimney, should be operated
within the limitations set down by the design parameters in order to prevent possible damage
to the flue or structural parts.
If future conditions require operation outside the limits given in the above then the possible
change should be referred to the builder before the change is made, for their design review
of the consequences.
A minimum flow requirement arises from the need to maintain a sufficiently high outlet
velocity for the gases to rise an adequate height above the chimney, particularly if near-
inversion or strong wind conditions pertain, and to prevent them falling back around the top
of the chimney. This situation may also occur if the operating temperature is too low: there
can also be too low an outlet temperature if the flow is too small, due to excessive heat loss
and temperature drop through the height of the chimney.
 GAS CONDITIONS

To be inserted by power station owner

 2. SECTION INDEX

MAINTENANCE PROCEDURES

2.0 Routine Maintenance.

2.0 Removal of Temporary Covers

2.0 Lift Maintenance

2.0 Store Items

2.0 Tools

2.0 Special Equipment

2.0 Inspection and Test Records

 SUB SECTION 3.1

ROUTINE MAINTENANCE.

2.0.0 Inspection and Maintenance

2.0.0 General Notes

2.0.0 Initial Inspection

2.0.0 Annual Maintenance Schedule

2.0.0 Inspection

2.0.0 Tri-annual Maintenance Schedule

2.0.0 Maintenance Schedule on Flue

Shutdown

2.0.0 Lightning Conductor System

2.0.0 Electrical System

3.1.1 INSPECTION AND MAINTENANCE

The chimney should be considered as an essential piece of power station plant. Some of the
keys to operational longevity, in addition to proper operation, are continuous and assiduous
inspection and maintenance. Although a number of the items discussed below can usefully
be carried out by the station staff, in general detailed chimney maintenance should be carried
out by an experienced company. Inspection and maintenance would normally be considered
under two schemes, with further sub-division depending on whether or not the chimney is in
operation. At any shutdown the opportunity should normally be taken to carry out a complete
inspection of those parts of the chimney, which are normally not accessible. Note that these
operations are best carried out after careful planning, so as much notice as possible should
be given to the inspecting agency of the times when the inspection should be carried out.
The results of all inspections and the details of any maintenance or repair work carried out
should be recorded in a formal Maintenance Logbook. These records at the time of the
inspection should be signed by the inspector or by representatives of the agency carrying out
the inspection and by the station Maintenance Supervisor. The Logbook should be in pro-
forma style to ensure that all items are appropriately covered, and the forms should be
amended following any future modifications to the chimney structure.
The style of the Logbook should also be such that comparisons can readily be made
between the individual inspections of a series, since the first warnings of impending problems
can often be given by an abrupt change in previously stable characteristics.
The following Maintenance schedules suggest that inspection be based on an annual and on
a tri-annual basis, with the major items being on the latter. However it is suggested that all
items should be carried out on a six-monthly basis for the first 18 months of chimney
operating life, before reverting to the schedule proposed. Moreover, if there is to be a
protracted period after completion of construction before operation commences, then
consideration should be given to having relevant items of the tri-annual service carried out
before commencement of operations.

3.1.2 General Notes.

Because of the proximity of hot and corrosive gases emitted from the liners it is essential that
when personnel enter the chimney, even for a routine inspection, that they do so only after
the issue of a formal written permit to be signed by the Station Supervisor and that the
station operating personnel are also formally aware that an inspection is taking place.
The aircraft warning lights should be inspected from ground level on a very regular basis,
perhaps weekly, by a member of the regular station personnel who is designated to carry out
this task.
Although the chimney has been designed to resist severe earthquakes, should a major
quake occur then it is recommended that the tri-annual inspection schedule be initiated at the
earliest possible opportunity. A brief internal check should of course take place immediately.
HOWEVER NO ATTEMPT WHATSOEVER SHOULD BE MADE TO LOAD THE ROOF IN
EXCESS OF THE SPECIFIED DESIGN LOAD OF 0.5 TONNE / M2 OF EFFECTIVE AREA
WITHOUT REFERENCE BACK TO THE BUILDER. This represents a total load of 7.0
tonne spread equally over the whole roof area.
If the insulation is removed from any part of the steel flue during inspection or maintenance
operations, then it is essential that this is wholly replaced on completion: there is potential
danger to personnel in touching such spots.
Although the following schedules detail what should be carried out, and when, the methods
of inspection for a number of major items are given in separate Appendices, and have
generally been prepared by other organisations:
Any waste materials arising from inspection and maintenance operations during shutdown
phases should be handled in accordance with local regulations and good practice.

3.1.3 Initial Inspection.

This brief inspection is intended as a final check before the flue is put into service, either for
the first time or after maintenance works.
• Check lateral restraint arm fittings
• Check drainage pipe is open.
• Check the lift is working.
• Check the expansion joint is undamaged.
• Check the electrical panels.
• Check no one is in or on the chimney and then lock the base door and hand the key to the
Maintenance Manager.

3.1.4. Annual Maintenance Schedule.

Assuming that the flues are in operation, the following items should be inspected, with
reporting as described earlier. Remember that the flue surfaces may be very hot under the
insulation, so take due care if this is loose or is removed. Neither open manholes or rodding
eyes or sample ports, nor look over the top of the flue unless you are certain that the flue is
not in operation, and you have a written permit from the Station Supervisor to do so. No other
access facilities than those already provided should be necessary for this.

3.1.5. Inspection.
• Make general visual inspection of all items at each of the floors
• Oil locks and door hinges on doors, safety gates, and any manholes, if fitted. Do not open
manhole without written permit from operating staff
• Depending upon the manufacturers' recommendations, consider replacing all lighting
bulbs
• Try to identify source of any unusual rubbish, and sweep all floors
• Check that the roof outlet drain pipes are not blocked
• Check lightning conductor system.
• Check the top of the liner and the insulation claddings. BEWARE that the liner cans
projecting at the roof may be hot even on the outside.
• Check projecting flue tops if necessary
• Inspect those parts of the lift cage, enclosures and tower that are visible from the
platforms to see that nothing is missing or damaged. Report any unusual noises during lift
operation.
• Check Aircraft Warning Lights are functioning and maintain if necessary.
• As far as is possible from the platforms check that the flue insulation is complete and
secure.
• Carefully remove insulation at gas sampling ports and check metalwork for any sign of
corrosion: do not touch metal.
• Take clear colour photographs for a year-by-year check on any changes.
• Carefully replace all insulation panels removed for inspection
• Check that the flue is not touching the metalwork where it passes through the openings in
the floors.
• Carefully inspect inside of electrical panel, and report any sign of burning or blown fuses.
Do not touch any electrical components

3.1.6. Tri-annual Maintenance Schedule.

This is in addition to, or as extension of, the annual schedule, to which reference MUST be
made for warnings etc. This inspection will require the provision of specialist access
equipment, and activities that are probably outside the normal scope of station maintenance
staff. It is recommended that a full photographic record should be kept of important parts of
the chimney at this inspection for a time-by-time review.
• Check all bolts in handrails, staircase, ladders, floor beams, and the platforms.
• Check that all floor grating panels are securely fastened to the support Steelwork
• Check all exposed metalwork above the roof, and the louvres in the shell at the top for
signs of corrosion and tightness of bolts
• Repaint top outside surface of windshield and projecting flues with heat and acid resisting
paint if necessary
• Check roof paint and repaint if necessary.
• Inspect all outside and inside concrete surfaces for signs of spalling or reinforcement
corrosion; if any is found, cut out all loose material, thoroughly clean all exposed
reinforcement, and repair with non-shrink material in accordance with manufacturer's
instructions
• Using a thickness meter or ultrasonic, check the thickness of the steel flue plate at
locations, which are readily reached at each floor or platform level.
• Check that the flue insulation is complete over the whole surface of the flues and inlet
ducts, and that there are no signs of bare metal: this will require selective removal of the
cladding over the inlet insulation
• Check that all gaskets at manholes and ports and hopper are gastight
• Carry out safe load tests on hoists and other lifting devices
• Check that no unauthorised loads have been applied to roof or floor structures
• Inspect floor and flue inlet support bearings for full seating of bearings, any signs of
corrosion, or any signs of cracking in surrounding concrete; any problems here should be
reported to the builder for their review

3.1.7. Maintenance Schedule on Flue Shutdown.

• Note that without the use of forced cooling of some type, it could take several days for the
temperature in the flues to drop to a level at which men can safely enter.
• Check that the expansion joint between flue sections, including its seals and mineral wool
insulation, are complete. This may require the local removal of insulation.
• Check the inside of the steel inlet duct sections for signs of corrosion, and use a thickness
meter to determine if any overall corrosion has taken place; these tests should be done at
the same point at each inspection. Particularly careful checks should be made at external
reinforcing rings, such as at support points. This inspection will require the removal of the
cladding on the outside of the insulation, so appropriate tools will be necessary for this
and its subsequent replacement
• Remove insulation on the outside face opposite problem areas located by the internal
inspection and record condition of steel plate.
 • Give consideration to washing inside face of flues, though this should not automatically be
done.

3.1.8. Lightning conductor system.

These maintenance checks should be carried out as an integral part of the annual
maintenance schedule. Check the system for tightness of all screwed connectors at all floor
levels and at the roof. Carry out impedance test to all the down conductors at the test clamp
locations, at ground level. Make entries in the Maintenance log book and also report findings
to the Duty Supervisor.
The maximum resistance when testing electrical continuity should not exceed about 1 ohm.
Notes:
Testing should not be carried out in a season when thunderstorms are most frequent
During testing the minimum number of disconnections for testing purposes should be made
in accordance with the requirements.
After each of these tests have individually been carried out, the ends of all conductors
concerned are to be thoroughly cleaned and securely re-bonded to the terminals, ensuring
that all screws are properly tightened; a corrosion inhibitor should be used where necessary.
0. Disconnect the screws from all terminals which are attached to the windshield inside face
concrete and carry out continuity tests between neighbouring terminals
2. Electrical continuity testing should be carried out from floor to floor, by disconnecting
convenient terminals on adjacent floors and testing between them.
3. Continuity tests should be carried out between the down conductors entering at the base
of the chimney on the outside face and connected to the test clamps and the earth
bonding system.
4. Carry out electrical continuity tests between the bonds on the flue inlets and their earthing
with the reinforcement.
5. Carry out a thorough visual inspection of the air termination to the liner cans projecting
above the roof.
6. Carry out a visual inspection of all metallic joints, checking that all nuts, screws and lugs
are securely fastened and free from corrosion. Take particular care with external joints
and junctions between dissimilar metals.

3.1.9. Electrical system.

To be inserted by electrical supplier
 SUB SECTION 3.2

REMOVAL OF TEMPORARY COVERS.

 CHIMNEY

Method Statement on the Dismantling of the Removable Cover at the top of West Liner Can.

Reference Drawing N° *********

The work involved in removing the removable cover from the top of the West liner can (EL
+210.0m), must be undertaken by an approved contractor versed in the requirements of working
at heights.

Work sequence:

• Set up site.
• Induction of specialist personnel.
• Access to roof via Alimak Permanent lift.
• Set up a 1 tonne winch to transport material on the outside of stack.
• Set up method statements on procedure to dismantle.
• Set up Job Safety Analysis procedures.
• Hazard Risk Assessment.
• First Aid Facilities.
• Use Personal Protection Equipment.
• Safety Harnesses must be worn whilst working at heights.
• Lift scaffold components using the 1 tonne winch system.
• Install full circumferential scaffold access platform at West liner.
• Install Safety nets.
• Set up inertia lines at the top working level of the access staging at roof level.
• Prepare to dismantle.
• Provide necessary tools and equipment to assist in the dismantling.
• Remove the top circumferential side flashing sheets.
• Access the top of removable cover and remove the 1mm thick stainless steel covering
sheet.
• Lower removed sheets to ground.
• Remove the 20mm thick plywood sheets.
• Cut plywood sheets to manageable sizes and lower to ground.
• Unbolt galvanised purlins from cleat positions.
• Lower galvanised purlins to ground.
• Remove circumferential cleats using grinders.
• Remove 200 x 100 x 10 cleat plates from the top of the liner can.
• Remove center support beam assembly and lower to ground.
• Final check to ensure that all componente from the removable cover is dismantled.
• Dismantle access scaffolding and systematically lower to ground.
• Remove all construction from roof level.
• Close access hatch cover on completion of works.
• Remove 1 tonne winch system.
• Demobilise and clear site.

Note:- Prior to commencing the erection or storage of scaffolding at the roof level ensure that
the protective membrane applied to the roof surface is adequately protected. Scaffold uprights
and base plates must be seated on timber battens.

The above sequence of works involved in the dismantling of the removable cover is purely a
generic guideline and is open to interpretation by the appointed specialist contractor ti suit his
own working procedure.

1
 SUB SECTION 3.3

LIFT MAINTENANCE

The Alimak maintenance manual

to be inserted here
 CHIMNEY

SUB SECTION 3.4

STORE ITEMS

1
 CHIMNEY

2.3 STORES ITEMS

The recommended consumable spares to be available for routine maintenance are listed in
Section 5 of this manual. Long ‘lead time’ items (insurance spares) are also listed for
maintenance back up. Full overhauls may require comprehensive surveys and bills of
replacement materials generated accordingly
 CHIMNEY

SUB-SECTION 3.5

Tools
 CHIMNEY

2.3 TOOLS

For the purposes of routine maintenance there are no special tools required.

Normal hand tools will suffice if required to carry out routine maintenance tasks described in
Section 3.1.
 CHIMNEY

SUB-SECTION 3.6

Special Equipment
 CHIMNEY

2.3 SPECIAL EQUIPMENT

For routine maintenance, special equipment is not required.

 CHIMNEY

SUB-SECTION 3.7

Inspection and Test Records

 CHIMNEY

2.3 INSPECTION AND TEST RECORDS

As the manufacturing ITPs contain data please refer to the Inspection and Test Records issued
separately.