1.0 Task Overview
1.1 Component type
This work instruction is applicable to various dampers.
1.2 Equipment tag or unique equipment identifier
Ensure unique equipment identifier is used to designate which damper is being worked.
1.3 Scope
This work instruction describes inspection, cleaning, lubrication and minor maintenance of dampers.
1.4 Develop list of know consumable materials to be used
A. Clean lint free rags
B. Grease (e.g. Mobilux EP #2, vendor approved) C. Cleaning solvent (Vendor approved)
D. Brush
E. Oil (Vendor approved)
1.5 Develop a list of know parts to be replaced
A. Gaskets B. Seals C. Packing
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1.6 Special tools
A. Mechanic’s tool box B. Grease gun
C. Can oiler
D. Ladders, scaffolding (depending on location) E. Safety belts
2.0 Pre-job Brief
2.1 Evaluate potential for generation or equipment risk hazards
A. Some fans have resonant frequencies. Belts should be adjusted appropriately to avoid fans potentially running at resonant frequencies.
B. Some belts do not recommend the use of belt dressings. This could cause premature belt failure. (refer to belt manufacture with respect to belt dressings) C. It is recommended that belt tension be checked within 24 to 48 hours of installing
new belts due to belt break-in stretch.
D. If ventilation fans are being worked, resulting ventilation line-ups to support work can cause significant d/p’s across doors or other accesses posing a personnel safety hazard.
2.2 Identify Foreign Material Exclusion (FME) potential and mitigation
A. If work is performed inside plenums foreign material exclusion areas should be established.
2.3 Job Safety Analysis, Identifies general and specific hazards
A. Conduct a pre-job brief to ensure the scope of the work to be performed is understood by all personnel.
B. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work.
2.4 Identify permits required
A. Equipment Clearance/Tag out Orders
B. Chemical Control Procedures (handing and disposal)
2.5 Identify Environmental Consideration
A. Refer to Material Safety Data Sheets (MSDS) for proper handling and disposal of special chemicals (E.g. cleaning solvents)
B. Handling and disposal of chemicals (E..g. solvents, oil, grease, cleaning materials, etc) should be in accordance with approved chemical control procedures
2.6 Identify Operating Experience
Review any relevant plant specific or industry related operating experience applicable to the work being performed and the use of the tube cleaning equipment.
2.7 Identify Clearance/Tag out Boundary
A. Motive force to damper (breaker, air supply) B. Power to FD or ID fan(s)
3.0 Contingency Considerations
3.1 Identify potential scope expansion and actions due to scope expansion
A. Inspections of any components may result in the need to repair or replace components as appropriate.
B. Additional work identified during the performance of this work instruction requires a scope change to plan newly identified work.
3.2 Identify individuals to contact in case certain events occur
A. Contact planner if scope growth is identified during work instruction performance B. Contact supervision for any uncertainties with respect to the repair or replacement
of worn or damaged parts identified during work instruction performance.
C. Contact vendor for any clarification of vendor information or additional vendor assistance is required
3.3 Identify rapid or emergency actions to place equipment in likely compensatory configurations or conditions
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3.4 Develop material list for potential contingency and consumable parts
A. Bearings B. Shaft
4.0 Detailed Work Instructions
Develop work instructions, utilize existing procedures when applicable Provide expected actions in proper sequence for task.
Identify Notes and Cautions where needed
A. NOTIFY Operations prior to beginning work
B. ENSURE an appropriate clearance/tag out is in place to perform work safely C. ENSURE all parts expected to be used are available and in hand
D. ENSURE all tools necessary to perform the job are available
E. ENSURE appropriate personal safety equipment is worn and used on the job 4.1 Inlet Damper Clean/Inspection
A. DISCONNECT damper linkage from actuator.
B. CLEAN blades and linkage(s) using vendor approved method of:
a. Dirt/dust/ash/etc b. Old grease
C. INSPECT the damper components:
a. INSPECT linkages for:
1. Inadequate lubrication
2. Verify free of obstruction or binding
3. Missing or broken parts (pins, bolts, fasteners, etc) 4. Proper alignment
b. INSPECT blades for:
NOTE
Any damaged or degraded components should be evaluated for replacement.
Work instruction should be amended to perform corrective maintenance.
NOTE
Reference vendor technical manual for approved cleaning methods: steam clean, water wash, sandblast, approved solvents
1. Corrosion 2. Erosion 3. Ash buildup 4. Cracks 5. Warpage
6. Seal along blade edges 7. Binding
8. Bending/buckling
9. Brittle/broken frayed seals (If installed on blades)
c. INSPECT blade seals
1. INSPECT in open and close position for straightness and obvious surface variations.
2. ENSURE blade seals provide continuous contact along entire blade length in the closed position.
d. INSPECT blade shaft
1. INSPECT shaft at bushing or bearing pint for wear 2. INSPECT for bowed shaft
e. INSPECT frame for:
1. Corrosion 2. Erosion
3. Warpage that may cause blade binding f. INSPECT packing glands for leakage
1. Repack glands as required
g. CLEAN accessible external surfaces of the damper unit h. CHECK damper mountings for loose, broker or missing parts i. INSPECT ductwork to damper seals for tightness
j. INSPECT inside portion of ductwork at damper for ash build up.
CAUTION
If inside of ductwork at damper is inspected for ash buildup CONFINED WORKSPACE requirements should be in effect.
NOTE
Seals (if installed) may be either metallic, silicone, rubber or plastic). Seal tightness may be checked by a smoke test.
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4.2 Damper Bearings
A. REMOVE damper bearing(s)
B. CLEAN bearing(s) by soaking bearing(s) in approved solvent to remove grease and dirt
C. SLOWLY ROTATE outer race noting any rough/sticky spots
D. DISASSEMBLE bearing.
E. INSPECT bearing for damage.
a. Broken or cracked rings b. Dented shields/seals c. Cracked/broken separators d. Broken/cracked balls or rollers
e. Flaked/spalled areas on balls, rollers or raceways f. Discoloration (brownish blue or blue-black areas) g. Indented/brinelled/etched raceways
4.3 Lubrication
A. LUBRICATE linkages B. LUBRICATE bearings
C. APPLY small amount of oil to all damper moving components NOTE
1. Soak sufficiently to loosen and remove grease/dirt 2. Use a brush to assist in removal of grease/dirt
NOTE
If rough/sticky spots persist after repeated cleaning attempts the bearing should be disassembled and inspected.
NOTE
If any of the following conditions exist, replace bearing.
4.4 Reassembly
A. INSTALL bearings (if removed) B. INSTALL linkages (if removed)
C. INSTALL all bolts, screws and fasteners (torque as specified) D. MANUALLY CYCLE damper open and closed and INSPECT for:
a. Smooth operation of linkage and blades b. Check for any binding or noise
c. Check completeness of travel d. Check mechanical stops
E. INSTALL guards, covers and access ports F. INSTALL linkage to actuator
G. SET Mechanical stops and electrical limits
5.0 Determine PMT and PMT considerations A. RELEASE Clearance/Tag out on damper
B. ELECTRICALLY CYCLE damper open and close and INSPECT for:
a. Proper operation of linkage and blades b. Unusual noise
c. Vibration
d. Proper setup of mechanical stops and electrical limits
C. VERIFY that dampers are synchronized, for double inlet or outlet damper configurations.
D. DISPOSE of any generated waste products properly.
E. RETURN any unused spare parts to stores/warehouse
6.0 Feedback Mechanisms
Identify mechanism to provide work order feedback for improvements and errors A. Perform post job review
B. Initiate any corrective action program documents necessary to resolve any problem areas identified.
NOTE
Damper synchronization is accomplished by establishing a reference dimension, actuating the vanes, and comparing the two sides for balance.
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7.0 References
A. Industrial Safety Manual
B. Damper vendor technical manual C. Actuator vendor technical manual D. Material Safety Data Sheets
E. Chemical Traffic Control Procedure