Reliability Centered, Multiple Year Preventative Maintenance Plan for Utility Boilers

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  • Topic: Boiler, Fire-tube boiler, Furnace
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  • Published : January 14, 2013
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Reliability Centered, Multiple Year Preventative Maintenance Plan for Utility Boilers: An Arctic Combustion Solution Arctic Combustion Limited, Milton, Ontario

Project Report by
Ashiqur R Khan (ID: 0441687) MANUF 701, Walter G Booth School of Engineering Practice McMaster University September 17, 2012 Version 4.0

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Declaration by Candidate
I hereby declare that this project report entitled Reliability Centered, Multiple Year Preventative Maintenance Plan for Utility Boilers: An Arctic Combustion Solution is the result of my own research except as cited in the references. Other sources of information (i.e. consultation with the supervisor and the senior engineers) wherever used have been acknowledged. General guidance was sought from the following personnel while preparing the section entitled Arctic’s Service Procedures and Methodologies. Harry Terpstra, Service Manager, Arctic Combustion Limited Craig Matthews, Account Manager, Arctic Combustion Limited Jim Buckel, Senior Engineer, Arctic Combustion Limited Janice Koehler, Application Engineering Manager, Lakeside Process Controls Chris Calvet, Sales Engineer, Maxon, a Honeywell Company, Toronto Branch

The project report has not been accepted for any degree and is not concurrently submitted in candidature of any other degree.

Ashiqur R Khan

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Executive Summary
Arctic Combustion Limited realizes that the ability of a heating and cooling plant to operate safely and productively is highly dependent upon the integrity of the boilers. In this business case, we enquired the opportunity of multiple-year preventative maintenance plan for utility boilers. The scope includes various sizes of fire-tube and water-tube boilers firing natural gas at a rate of 400,000 BTUH or higher. The target customer base includes but is not limited to hospitals, universities, large buildings with central heating and cooling systems. As a part of the project we presented a systematic approach to implement a Reliability Centered Maintenance (RCM) program to perform preventative maintenance on utility boiler units. The RCM is a process for determining action items to ensure a boiler unit in its current operating condition continues to perform its intended tasks. The construction of a Failure Mode and Effect Analysis (FMEA) Table was described. The FMEA Table is an effective failure record management and maintenance priority setting tool that can lead to the desired level of unit functionality and performance standard utilizing limited resources. We devised a maintenance package comprising of periodic tasks to be carried out by the boiler operators and maintenance crews. General procedures for maintaining integrity of boiler safety control components were also described in this report. Two case studies were presented with our proposed maintenance tasks and schedule. At the end of the report a benefit analysis is presented on choosing Arctic Combustion to perform boiler unit preventative maintenance for multiple years (i.e. 3-5 years; before negotiating another service scope and rate).

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Table of Contents
DECLARATION BY CANDIDATE ............................................................................................................................ I EXECUTIVE SUMMARY .......................................................................................................................................... II TABLE OF CONTENTS ............................................................................................................................................III STATEMENT OF PURPOSE ..................................................................................................................................... 1 THE ORGANIZATION INVOLVED ......................................................................................................................... 2 LIST OF PEOPLE...
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