Utility Checklist

UNITED BREWERIES LIMITED - NALANDA
PREVENTIVE MAINTENANCE TASKLIST

Order No :
Frequency: 3000 Hrs
Order Type : Preventive Maintenance Order
Date :
Equipment : Air Compressor
Functional Location: Utility
Cost Centre: Engineering
Operation Description: PM Plan for Air Compressor
Sl No ACTIVITIES TO BE PERFORMED STANDARDS FINDINGS REMARKS
1 Cylinder and cylinder heads Execution
2 Cylinder bore-Check for wear & ovality visual
3 Cylinder jackets-Clean and remove scale Execution
4 Cylinder Heads-Clean and remove scale Execution
5 Piston and piston ring- visual
6 Piston -Check bumping clearance visual
7 CI rings (Lube models)-Check end gap visual
8 Piston rod & packing rings visual
9 Piston -Check bumping clearance visual
10 Lub oil system Execution
11 CI rings (Lube models)-Check end gap Execution
12 Piston rod & packing rings visual
13 Piston rod-Check for Scoring visual
14 Oil wiper rings-Check for leakage and replace Execution
15 Running Gear Execution
16 Cross head-Check for wear & scoring visual
17 Cross head guide-Check for wear & scoring visual
18 Cross head pin and bushing-Check for wear & scoring visual
19 Main & con. Rod and bearings-Check for wear visual
20 Crankshaft-Check for wear visual
21 Lubrication running gear
22 Gear pump-Check wear of gear and bearing
23 Frame sump oil-Replace oil and clean frame
24 Heat exchanger
25 Tube bundle assembly-Clean scale & carbon check
26 Tube bundle assembly-Tubes for chaffing
27 Shell-Clean from inside
28 Air discharge piping
29 Air discharge bottle-Clean carbon
30 Air discharge pipe-Clean carbon
31 Safety valve-Clean operation
32 Drain cock-Drain moisture several times a day
33 AVM's-Replace
34 Metallic hose-Replace
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Signature of Operator:
Signature of Maintenance Engineer:
Signature of Engineering Head:
Order No :
Frequency: 1500 hrs
Date :
1 Air suction &discharge valve
2 Valve Assembly-Rebuild, replace/Recondition worn out parts..
3 Valve seat gasket -Replace
4 Unloading piston-Check for wear & lubricate
5 Piston 'O' ring-Check for wear & lubricate
6 Valve holder 'O' ring-Replace
7 Lub oil system
8 Teflon ring (Non lube model)-Check wear &rotate 120
9 Piston rod & packing rings
10 Piston rod nut-Check for tightness
11 Running Gear
12 Connecting rod nut, bolts & split pins-Check for tightness &locking
13 Lubrication running gear
14 frame sump level-Check level
15 Cartridge oil filter-Replace
16 Oil strainer-Clean
17 Oil transfer pipe-Replace 'O' rings
18 Lubricator and cylinder Lubrication (lube models only)
19 Lubricator oil tank -Check and refill
20 Oil lines cylinder lub.-Check for lessening and leakage
21 NRV at cylinder-Check for carbon &clean
22 Lubricator tank level-Check level and make up
23 Heat exchanger
24 O' ring and gasket-Replace
25 Drain trap-Check & clean strainer check for operation
26 Safety valve-Check for operation
27 Suction filter
28 Filter Element-Clean
29 Filter Element-Replace
30 Electrical Checks
31 Check & clean the contactor
32 Tighten loose connections.
33 Check earthling continuity
34 Check motor insulation & winding resista.
35 Grease bearings of the motor.
36 Check motor abnormal noise
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Order No :
Frequency: 500 ,4500and 6000 Hrs
Date :
Other (500Hrs)
1 Belt tension-check and Adjust
2 Motor Alignment-check and Adjust
3 Pressure Gauge-Inspect
4 Temperature indicator/controller-Inspect and tighten electrical connection
5 Oil.water,pressure switches-Check for operation
Piston rod & packing rings (4500Hrs)
6 Teflon packing mgs-Check for leakage and replace
Lubrication running gear
7 Oil -Clean scale
Cylinder and cylinder heads (6000Hrs)
8 Piston -Check piston for Lessening
Air discharge piping
9 Air Receiver-Clean
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Order No :
Frequency: 250 - 500Hrs
Date :
Equipment : Ammonia Compressor(KCX9)
Operation Description: PM Plan for Ammonia Compressor(KCX9)
1 Check proper funct. of OP/HP-LP cut out (250Hrs)
2 Check oil seperator & its float function
3 Suction filter (500Hrs)
4 KC/KCX Strainer
5 PC -Wire Type Filter
6 Discharge filter
7 KC/KCX-paper filter
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Order No :
Frequency: 1500 Hrs
Date :
Equipment : Ammonia Compressor(KCX9)
Operation Description: PM Plan for Ammonia Compressor(KCX9)
1 Repeating maint. steps of check A & B. (1500Hrs)
2 Water flow
9 Check end float clearance of crankshaft (5000Hrs)
10 Check oil pump assembly
11 Check high pr. safety valve to ensure no leak.
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Order No :
Frequency: 1500 Hrs
Date :
Equipment : EVAPCO
Operation Description: PM Plan for EVAPCO
1 check liquid line strainer
2 core filter expansion valve
3 water pressure / Temp.inlet
4 water pressure / Temp.outlet
5 Water flow
6 water pressure / Temp.inlet.
7 water pressure / Temp.outlet
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Order No :
Frequency: Quarterly
Date :
Equipment : Ammonia PHE
Operation Description: PM Plan for Ammonia PHE
1 Check of carrying bar condition
2 Check for correct torque in tightening bolts
3 Check for corrosion in frame and skid assembly
4 Open the PHE & Check for scaling on both circuits
5 Open the PHE & Check for any dents or abnormalities, corrosion in the plate profile
6 Open the PHE & Check condition of gaskets and record
7 Open the PHE & Check gasket gluing and gasket geometry
8 Check for leakages from inlet and outlet valves
9 Check for proper working of Temp. Gauges
10 Check for proper working of Pressure Gauges
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Date :
Equipment : PUMPS
Operation Description: PM Plan for PUMP
Pump
1 Vibration or noise from the pump bearings.
2 Check foundation bolts for security of attachment and corrosion
3 Check for the proper functioning of the valves provied in suction and discharge
4 Check for any leakage from the seal
5 Open pump and check for the condition of the mechanical seal
Instrumentation / Valves
6 Check functioning of all actuated valves
7 Check for leakages from valves
Electrical Checks
8 Check & clean the Contactor
9 Tighten loose connections
10 Check earthing continuity
11 Motor insulation & winding resistance
12 Check and record current and tighten terminals of motor
13 Grease bearings of the motor
15 Check for proper working of interlocks
Instrumentation / Valves (Annual)
16 Calibration of haze meter
17 Calibration of flow transmitter
18 Calibration of pressure transmitter
19 Calibration of temp indicator (PT 100)
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Order No :
Frequency: Monthly & Half Yearly
Date :
Equipment : Cooling Tower
Operation Description: PM Plan for Cooling Tower
1 Check for Cooling Tower Body Vibrations
2 Check condition of nozzles.
3 Check condition of fins.
4 Check & clean the contactor with ctc.
5 Check & note the relay setting.
6 Tighten Fan Motor Connections.
7 Check earthing connection
8 Check motor noise level
9 Check perforated screen&sieve frames .
10 Check fan blade condition and locking (Half Yearly)
11 Oil change if required.
13 Check inlet distribt. Plate
14 Check foundation fasteners.
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Order No :
Frequency: Yearly
Date :
Equipment : Cooling Tower
Operation Description: PM Plan for Cooling Tower
1 Gear oil replacement.
2 Blade angle adjustment.
3 Nozzle replacement if required.
4 sump & basin cleaning.
5 Chemical dosing.
6 Fins cleaning.
7 Motor alignment
8 Check the condition of dead box.
9 Check the hollow rubber spring.
10 Check funct. of anti vibrating pads
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Frequency: Quarterly & Annual
Date :
Equipment : Cooling tower pumps
Operation Description: PM Plan for Cooling tower pumps
1 Pump
2 Vibration or noise from the pump bearings.
3 Check foundation bolts for security of attachment and corrosion
4 Check for the proper functioning of the valves provied in suction and discharge
5 Check for any leakage from the seal
6 Open pump and check for the condition of the mechanical seal
7 Instrumentation / Valves
8 Check functioning of all actuated valves
9 Check for leakages from valves
10 Check & clean the Contactor
11 Tighten loose connections
13 Motor insulation & winding resistance
14 Check and record current and tighten terminals of motor
17 Check for proper working of interlocks
18 Instrumentation / Valves (Annual)
19 Calibration of haze meter
20 Calibration of flow transmitter
21 Calibration of pressure transmitter
22 Calibration of temp indicator (PT 100)
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Date :
Equipment : CO2 NH3Compressor
Operation Description: PM Plan for CO2 NH3Compressor
4 KC/KCX Strainer
6 Discharge filter
9 Water flow
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Frequency:
Date :
Equipment : CO2 Compressor
Operation Description: PM Plan for CO2 Compressor
4 KC/KCX Strainer
6 Discharge filter
9 Water flow
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Date :
Equipment : VAM
Operation Description: PM Plan for VAM
1 Check working of all the safeties and there settings
2 Check all the set point values on the control panel.
3 Check current drawn by absorbent, refrigerant and purge pump
4 Measure the absorbent pump pressure and record the vapour temperature.
5 Analyze the LiBr solution & maintain corrosion inhibitor level and alkalinity.(LiBr Solution testing.)
6 Check for presence of octyal alcohal. Charge it, if required.
7 Clean The Steam Trap on Machine
8 Check/clean Purge pump & moisture trap on purge line.
9 Check steam control Valve operation.
10 Check Pneumatic circuit for leakages.
11 Check valve leakages
12 Check all valve for smooth operation
13 Check all RTD's for proper working
14 Check all Pressure gauges for proper working.
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Order No :
Frequency: Annual
Date :
Equipment : VAM
Operation Description: PM Plan for VAM
1 Cleaning Of View Glass.
2 Overhauling of absorbent & refrigerant pump.
3 Clean the steam Trap on M/c.
4 Overhauling of Purge Pump.
5 Clean moisture trap on Purge line.
6 Clean steam control valve sheet.
7 Remove entire LiBr from M/c and settle it. Based on LiBr quality decide filtration/ settling.
8 Replacement of Rubber components like diaphragms, gasket, etc
9 Conduct bubble test on M/c.
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Order No :
Frequency: 250 Hrs
Date :
Equipment : DG-1010kVA
Operation Description: PM Plan for DG-1010kVA
1 Engine Valve Lash - Inspect/Adjust
2 Fuel Injector - Inspect/Adjust
3 Battery Electrolyte Level - Check
4 Belts - Inspect/Adjust/Replace
5 Cooling System Coolant Sample (Level 1) -
6 Obtain
7 Cooling System Supplemental Coolant Additive
8 (SCA) - Test/Add
9 Fan Drive Bearing - Lubricate
10 Radiator - Clean
11 Engine Air Cleaner Element (Dual Element) -
12 Clean/Replace
13 Engine Oil Sample - Obtain
14 Engine Oil and Filter - Change
15 Engine Protective Devices - Check
16 Fuel System Secondary Filter - Replace
17 Heat Shield - Inspect/Replace
18 Hoses and Clamps - Inspect/Replace
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Order No :
Frequency: 2000 Hrs
Date :
1 Engine Mounts - Check
3 Generator Set Vibration - Inspect
4 Generator Set Vibration - Test/Record
5 Insulation - Test
6 Stator Lead - Check
8 Obtain
9 Generator Bearing - Lubricate
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Date :
1 Cooling System Coolant Sample (Level 2) (500Hrs)
2 Engine Crankcase Breather - Clean
3 Fuel System Primary Filter (Water Separator)
4 Element - Replace
5 Cooling System Coolant (DEAC) - Change (3000Hrs)
6 Cooling System Coolant Extender (ELC) - Add
7 Cooling System
8 Alternator - Inspect (6000Hrs)
9 Prelube Pump - Inspect
10 Speed Sensor - Clean/Inspect
11 Rotating Rectifier - Check
12 Cooling System Coolant (ELC) - Change (10000Hrs)
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Order No :
Frequency: 250 & 500 Hrs
Date :
Equipment : DG-500 kVA
Operation Description: PM Plan for DG-500 kVA
1 Engine Valve Lash - Inspect/Adjust (250Hrs)
3 Battery Electrolyte Level - Check
4 Engine Oil Sample - Obtain
6 Fuel Tank Water and Sediment - Drain
7 Hoses and Clamps - Inspect/Replace
8 Belts - Inspect/Adjust/Replace (500Hrs)
9 Cool Syst. Supplem.Coolant Addit.(SCA) Add
10 Cylinder Head Grounding Stud - Inspect/Clean/Tighten
11 Engine Oil and Filter - Change
12 Engine Protective Devices - Check
13 Fuel System Primary Filter (Water Separator) Element - Replace
14 Fuel System Secondary Filter - Replace
15 Magnetic Pickups - Clean/Inspect
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Order No :
Frequency: 2000 Hrs
Date :
1 Generator Lead (Round Cable) - Check (S/N:FSE1-Up
2 Engine Crankcase Breather - Clean
3 Generator Lead (Round Cable) - Check (S/N:FFH1-Up
4 Generator Set Vibration - Inspect
5 Insulation - Test
6 Radiator - Clean
7 Stator Lead - Check
9 Rotating Rectifier - Check
10 Varistor - Check
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Order No :
Frequency: 3000 , 4500 &10000 Hrs
Date :
1 Alternator - Inspect
2 Cooling System Coolant (DEAC) - Change
3 Cooling System Coolant Extender (ELC) - Add
4 Cooling System Water Temperature Regulator -replace
5 Crankshaft Vibration Damper - Inspect
6 Engine Mounts - Inspect
7 Engine Speed/Timing Sensors - Check/Clean/Calibrate
8 Engine Valve Lash - Inspect/Adjust
9 Engine Valve Rotators - Inspect
10 Starting Motor - Inspect
11 Turbocharger - Inspect
12 Water Pump - Inspect
13 Generator Bearing - Lubricate (4500Hrs)
14 Cooling System Coolant (ELC) - Change (10000Hrs)
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Order No :
Frequency: Monthly
Date :
Equipment : Husk Boiler
Operation Description: PM Plan for Husk Boiler
1 Bucket Elevator
2 Pit Cleaning
3 Bucket Bolt Tightening
4 Motor Gear oil Checking and top up
5 Coupling tyre and bolt checking
6 PA/FD/ID FAN
7 Coupling tyre and bolt checking
8 Bearing, bearing sleeve checking and Greasing
9 Duct air leakages checking
10 Feed Pump
11 Gland checking
12 Star checking
13 Strainer filter Cleaning
14 Furnace
15 Send cleaning
16 Nozzle Cleaning
17 Furnace cleaning
18 Boiler /Chimney
19 Boiler Water, Service tank water and storage tank water drain
20 Mobrey and gauge glass cleaning.
21 Safety valve checking on starting
22 Mobrey low level safety checking.
23 Boiler House Keeping
24 Boiler Tube Cleaning
25 All Gasket checking to avoid steam leakage from Boiler
26 Do Loto before Electrical work
27 Check & clean the contactor with ctc.
29 Tighten Fan Motor Connections.
30 Check earthing connection
31 Check motor noise level
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Order No :
Frequency: Half Yearly & Annual
Date :
Equipment : Husk Boiler
Operation Description: PM Plan for Air Husk Boiler
1 Bucket Elevator ( Half Yearly )
2 Bearing checkup
3 Furnace
4 Send Draining
5 Do Loto before Electrical work
7 Boiler /Chimney ( Annual )
8 Chimney Cleaning
9 Descaling of Boiler
10 Tube cleaning
11 Hydro Testing
12 Safety valve overhauling
13 Steam Stop Valve Lapping
14 Fusible plug inspection
15 ID/FD Fan servicing
16 APH/Economiser/Super heater overhauling
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Frequency: Monthly
Date :
Equipment : RO Plant
Operation Description: PM Plan for RO Plant
1 Inspection of unit for leak
2 Check conductivity meter
3 Check ORP meter
4 Check & Clean the Cartridge filter
5 Check the Water flow meter
6 Clean the feed water line Strainer
7 Check the victory Coupling Gasket
8 Check the Pressure Gauge
9 Clean the Reject & Permeate water flow meter
10 Check the all Butter fly valve
11 Check the Foundation Nut & Bolt Tighten
12 Check any leakage the pipe line joints
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Frequency: Quarterly ,Half yearly and Annually
Date :
Equipment : RO Plant
Operation Description: PM Plan for RO Plant
1 Change filter Cartridge
Remove all membrane for
2
flushing with water
3 Profiling of Membrane
4 Dosing Pump -Clean& Check the Adapter
5 Dosing Pump -Check & Tight the Diaphragm
6 Dosing Pump -Check the Any leakage the Dosing pipe
7 Dosing Pump -Check & Clean the NRV
8 Do Loto before electrical work
15 Cleaning of membrane with chemical. (citric acid, sodium tri phosphate & ammonia buffer) (Half yearly)
16 Replacement of O rings of unit.
Checking RO Membrane condition,replace if necessary ( Annually)
17
18 MGF Cleaning
19 ACF Cleaning.
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Frequency: Monthly & quarterly
Date :
Equipment : Softener
Operation Description: PM Plan for Softener
1 Check the Leakage from Multiport pot valve
2 Check and clean the Nozzle strainer
3 Check Resin Leakage
4 Check Foundation Nut & Bolts
5 Check Pressure Gauge.
6 Cean the Flow Meter
7 Check spider coupling
8 Check The Agitator coupling.
9 Check the Agitator shaft.
10 Check for Agitator motor abnormal noise
11 Resin cleaning & Top up.
12 Raw Water storage Tank Cleaning
13 Soft Water storage Tank Cleaning
14 Salt room pump maintenance (quarterly)
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Frequency: Monthly
Date :
Equipment : Fire hydrant
Operation Description: PM Plan for Fire hydrant
1 MECHANICAL CHECKS
2 Check gland/Mech seal leakage
3 Check gasket leakage through casing
4 Check alignment of pump & motor
5 Check coupling spider condition
6 MECHANICAL SEAL CHECKS
7 Check seal faces
8 Replace Teflon seal ring if required
9 Grease the bearings
10 Do loto before electrical work
11 Check & clean the cont actor
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Frequency: Quarterly & Annually
Date :
Equipment : Fire hydrant
Operation Description: PM Plan for Fire hydrant
1 MECHANICAL CHECKS
2 Checking for alignment. (Quarterly)
3 Check for vibration.
4 Nut & Bolts tightening
5 Nut & Bolts greasing
6 Spider or Bush checking.
7 Impeller Lock nut tightening (Annually)
8 Check shaft & shaft sleeve for scoring.
9 Check coupling for wear.
10 Check bearing condition, replace if necessary
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Frequency: Monthly & Quarterly
Date :
Equipment : Forklift
Operation Description: PM Plan for Forklift
1 Brake &inching pedal to be checked for free travel (Monthly)
2 Check parking break
3 Check lubrication oil level of the engine
Check engine cooling system. Make sure that radiator Cock and water drain in the
4 cylinder block are closed.
5 Check hydraulic sump tank level
6 Check lift & tilt operation of lift & tilt cylinders.
7 Check the automatic transmission fluid level in Transmission
8 Make sure that fuel line connections are secure.
9 Check fuel lines for obstructions &leaks.
10 Replace hydraulic sump tank hydraulic oil & filter element. ( Quarterly)
11 Drain the transmission fluid. Remove &clean transmission Sump screen.
12 Clean plug of all foreign matter. Refill transmission with new transmission fluid
13 Replace The transmission fluid filter element.
14 Check the steering and make adjustments.
15 Inspect exhaust pipe and muffler for damage, leakage,
16 Security of mountings.
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Frequency: Annual
Date :
Equipment : Forklift
Operation Description: PM Plan for Forklift
1 Clean and repack the axle end bearings with grease .
2 Check the parking break adjustment.
3 Check condition of brake adjust, if necessary.
4 Inspect pressure cap of the radiator for proper sealing .
5 Inspect pressure cap for freedom of operation. Inspect & clean cooling system.
6 Check engine performance
7 Carry out "hydraulic system checks".
8 Clean & repack the steer axle bearings with grease .
9 Check the transmission performance.
10 Check lift carriage and upright adjustment.
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UNITED BREWERIES LIMITED - NALANDA

PREVENTIVE MAINTENANCE TASKLIST

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