1、3535789 0203582 TL)b DEPARTMENT OF THE ARMY TECHNICAL MANUAL REPAIRS AND UTILITIES PREVENTIVE MAINTENANCE FOR HEATING PLANTS AND SYSTEMS HEADQUARTERS, DEPARTMENT OF THE ARMY AUGUST 1958 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-W 3535789 020358
2、3 982 W HEADQUARTERS, DEPARTMENT OF THE ARMY WASHINGTON 25, D. C., 18 August 1958 I TECHNICAL MANUAL No. 5443 REPAIRS AND UTILITIES PREVENTIVE MAINTENANCE FOR HEATING PLANTS AND SYSTEMS Paragraph Pue SECTION I. GENERAL Purpose and objectives . - 1 2 General application . 2 2 Frequencies and procedur
3、es 3 2 Heating supervisor . . . - 4 2 Broad considerations . 5 2 Planning . 6 4 Execution 7 6 5 Records . 8 II. ESTABLISHMENT OF PROGRAM III. PROCEDURES FOR PREVENTIVE MAINTENANCE AND TECHNICAL INSPECTIONS General Frequency of preventive maintenance visita .“ Operating and service instructions Facil
4、ities and equipment (general) . Boilers, furnaces, space heaters and water heaters Fuel burning equipment. . Accessories, fittings, and controls Electronic combustion safeguards Temperature control equipment System maintenance 9 7 10 7 11 7 12 8 1s 9 14 10 15 13 16 16 17 17 18 17 *This manuil supers
5、edes TM 5-643, 4 June 1947; TM 5845, June 1947; TM 5-647, 23 May 1947; and TM -49, 2 June 1947. 1 TAa 9168 -. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3515789 0201584 619 W SECTION i GENERAL 1. Purpose and Obiectiver This manual provides opera
6、tional techniques, practices, and procedures for preventive maintenance of heating plants and systems which will assur+ a. Efficient operation and maximum utilization. b. Adequate care to avoid expensive and untimely repair or c. Elimination of hazards to life and property. d. A systematic collectio
7、n of data which can be used to plan work and to analyze the effectiveness of the preventive main- tenance program. 2. General Application Preventive maintenance definitions, policies, and procedures for general application are in AR 420-22. Supervision of heating plants and systems is a function of
8、the domestic heating plants unit of the mechanical section as set forth in SR.420-60-2. 3. Frequencies and Procedures The preventive maintenance inspection and service frequencies, procedures, and practices in this manual are guides which may be modified to meet local requirements. replacement. 4. H
9、eating Supervisor This term is used throughout this manual to facilitate expression in explaining procedures and practices. Its use should not be construed as influencing the duties assigned to particular per- sonnel. (The individual in charge of maintenance (and opera- tion of heating plants and sy
10、stems will observe proper channels to correct unsatisfactory maintenance procedures by personnel not directly under his supervision.) 5. Broad Considerations The heating supervisor will- a. Take positive action to remove the cause of recurrent main- tenance problems as opposed to merely performing o
11、bvious re- Pai= ! 2 TAQO S1B -. Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-D 3535789 0203585 755 = b. Carry out preventive maintenance inspections and services so there is a minimum of interference with user activities. c. Provide for the accomp
12、lishment of as much work as possible during each preventive maintenance visit, and assure that pe- riodic spot checks, inspections, and services are made of all com- ponents of the heating facilities. d. Train maintenance personnel to improve their efficiency, and to observe safety practices. TAG0 B
13、15B 3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3535789 020L5Bb 691 = SECTION II ESTABLISHMENT OF PROGRAM 6. Planning a. A complete picture of the heating facilities is necessary for effective maintenance planning, In surveying these facilities
14、 (low pressure and low capacity high pressure steam systems, hot water heating systems, warm air furnaces, unit heaters, di- rect fired space heaters, and domestic water heaters), a study of record drawings, real property records (SR 735-73), and other data (par. 8) will simplify the job for the hea
15、ting super- visor. b. Considering the components of the heating plants and sys- tems, the heating supervisor will determine the scope of pre- ventive maintenance-what is to be done and who should do it. (Section III sets forth procedures for preventive maintenance services and technical inspections
16、; additional guidance is given in TMs 5-642, 5-644, and 5-646. Consult manufacturers litera- tere for preventive maintenance of special equipment.) c. While most of the heating preventive maintenance services are performed by personnel of the domestic heating plants unit, certain tasks are more econ
17、omically performed by other per- sonnel. Such tasks will be designated by the heating super- visor who, through coordination and inspection, assures ade- quacy of the work performed. In designating tasks for others (operators of heating equipment on a constant attendance basis, roving patrol operato
18、rs, using personnel (building occupants), building preventive maintenance teams) , the heating super- visor will be guided by their capabilities for doing the work re- quired. d. The tasks remaining will be those to be accomplished by the domestic heating plants unit. Generally, the personnel in thi
19、s unit are qualified and have the tools to perform the tasks re- quired. However, instances may arise where special skills or tools are required to service certain types of equipment, for instance electronic temperature control equipment. Where these exceed the capabilities of the unit prsonnel, thc
20、 technical assistance should be requested from the manufacturer. In planning the preventive maintenance work to be directly performed by the unit personnel, the heating supervisor : I . 4 TAG0 916B e 380 3 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-
21、,-,-3515787 0201587 528 . Prepares a wall chart showing functions which should be performed periodically and when. Fits the man-hours available in the unit to the work to be performed by the unit to assure that periodic inspections and services of all parts of the heating facilities are covered in t
22、he program. Divides the workload into written work assignments in the form of notebooks containing inspection and guide sheets (sec. III), special instructions, and space for remarks by workmen requiring decision of the heating supervisor. (The necessity for writing the work assignments cannot be ov
23、eremphasized, for until this is done there is no way to check the coverage of the program.) 7. Execution As a means of asuring coverage, the heating supervisor will maintain a record of assignments to workmen in the unit and check off tasks as they are completed. This record should show name of work
24、man, the task assigned, the scheduled completion date, and the actual completion date. 8. Records a. General. A good system of record keeping is essentia1 for safe, efficient, and economical operation of heating plants and systems, and for planning and executing an effective pre- ventive maintenance
25、 program. In addition to assignment notebooks, charts, and real property records previously mentioned, the following are examples of records which have been found useful to heating supervisors : b. Examples. Location map. A map dividing the installation into zones provides a simple means of locating
26、 the equip ment to be maintained. (Mount the map on a conven- ient wall in the domestic heating plants unit; use the map in preparing schedules and work assignments; and establish a simple procedure for keeping the map up to date.) Equipment lists. Lists of heating equipment showing type, building l
27、ocation, and manufacturer, which are useful for scheduling prevent.ive maintenance inspec- tions and services. Master chart. The wall chart referred to in paragraph 6d(l) may also be used to indicate, in addition, build- 3-83 4 Provided by IHSNot for ResaleNo reproduction or networking permitted wit
28、hout license from IHS-,-,-3535789 0203588 464 H . ings containing heating equipment to be maintained divided by groups according to areas and route se- quence. initials of persons who serviced the equipment. and when . (4) Preventive maintenunce work lists . These contain an itemized list of the com
29、ponent parta of each type of heating system or equipment. designed to facilitate the performance of services . For example. if a preventive maintenance work list were prepared for a hand.fired. coal burning. hot water boiler. of which there may be several at an installation. the Lst would include: I
30、tem No . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Itan Operating and aervice instructions Flues and breeching Boiler room Electric motors Draft damper, ashpit door. and ashpi t. Grates Feed door and over-fire draft slide -. Air leaks Tubes, flue passes, and smokebox Refractory. co
31、mbustion chamber. and firepot Electric switches and fuses Check damper Altitude (pressure) gage and thermometer Water feeder and low water cutoff Relief valves Limit control Expansion tank Indoor thermostat Circulating pump control Piping Valves Radiation Circulating pump test suspected leaks with m
32、atch flame. Correct as required. Open cleanout doors and examine flue passes, tubes, and smokebox or breeching connection for soot and fly ash. Clean or arrange for cleaning as required. Examine firebrick or plastic refractory for any breakage or damage. Examine sections of cast iron furnaces for cr
33、acks or leaky joints. Check accessible parts, upper part of combustion drum and heat exchange surfaces of steel furnaces, and space heaters a. Draft Damper, Ashpit Door, and Ashpit. e. Tubes, Flue Passes, and Smokebox. f. Refractory, Combustiom Chamber, and Firepot. 9 TAGO 916B . * -. Provided by IH
34、SNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-= 3515789 0203592 995 W for signs of warping, leaking, and buckling, especially around feed opening. See that brick guards are in proper position. Arrange for replacement of any damaged or missing refractory. g. Dire
35、ct-draft Damper. If furnace is equipped with direct- draft damper, examine for proper operation. Be sure it closes securely. Correct if necessary. h. Radhtor Cleanouts and Radiator. Examine cleanout covers for tight fit. Examine interior of radiator with flashlight. When necessary, clean with flue b
36、rush, or arrange for vacuum cleaning if required. Replace covers tightly. i. Firebrick (Armg No. 1 and No. 4 Space Heaters). Examine firebrick for any breakage or damage. Arrange to replace dam- aged tiles as soon as possible. Check flue tiles on Army No. 1 space heater for ashes or coal spilled in
37、back of tile; let heater burn out and clean, if necessary. Examine steel liners back of flue tiles for proper position. j. Space Heater Body. Examine heater body for warping or rusting. Determine cause of warping and correct or arrange for correction. If rusty, notify user to have stove polished. k.
38、 Draft Door (Army No. 1 Space Heater and Cannon Stove). See that draft door assembly is in proper operation and make sure that spring holds door firmly in place. Arrange for re- placement of damaged parts. 14. Fuel Burning Equipment Examine forced draft blower inlet damper for proper setting. Adjust
39、, if required. If not running, start blower with manual control switch and listen for undue noise or vibration. Correct as required. a. Hand Fired. b. Stokers. (1) Stoker operation and lubrication. Investigate any in- dication of improper operation. See that air adjust- ment on fan inlet is tight an
40、d dampers in air tube operate properly. Check lubricant in motor and fan bearings, transmission, and feed-screw bearings. Lubri- cate in accordance with manufacturers recommenda- tions. Remove foreign matter from around drive mech- anisms. If stoker is in need of repair, arrange to correct the condi
41、tion. (2) Tuyeres and dead plates. Check tuyeres and dead plates for burning, warping, or blocking of air holes. Clean air holes, or arrange for replacement of tuyeres, if necmry. 10 TACO 916B Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-= 3511578
42、9 0203593 821 9 - C. oil BUrneT8. (1) Pot type vaporizing burner. Examine feedpipe and pot for carbon; and clean, if necessary. Operate clean- ing rod in feedpipe if burner is equipped with one. If excessive carbon has formed, check and adjust oil flow and draft in accordance with manufacturers in-
43、structions. Make sure pot is perfeltly level (if not, soot will form). Remove and examine strainer; clean as necessary. (2) Vertical rotary burner. Lubricate motor bearings in accordance with manufacturers instruction. Observe motor and burner operation. Turn off electric switches and inspect oil di
44、stributor, flame ring, and hearth of vaporizing (wall flame) type, or atomizing cup and hearth of atomizing (suspended flame) type burner. Clean off soot or carbon and correct any conditions causing improper operation like flame ring out of level, dirty oil, dirty cup, dirty or misalined electrodes
45、or gas pilot (TM 5-644). Examine for broken or cracked refractory. (3) Pressure atomizing gun type oil burner. Examine oil pump gland seal for leakage. Examine air inlet, elec- trodes, and nozzles and if necessary clean without re- moving these elements. Never use a metal needle to clean nozzle orif
46、ice. TM 5-644 contains detailed clean- ing instructions. If flame impinges on refractory and nozzle cannot readily be cleaned in position, replace with new element. If oil does not flow freely, turn off burner and remove and clean oil strainer. If air or oil adjustment is made, arrange to have burne
47、r reset with a flue-gas tester. (4) Horizontal rotary burner. Examine burner, atomizing cup nozzle and ignition electrodes of gas pilot; clean, if neccssary. Light burner and check for smooth, quick ignition. Flame should be clear o smoke and yellowish after stabilizing, but not extremely bright. A
48、white flame indicates excessive air. A very red flame with smoky tips indicates too little air. A trace of smoke immediately after ignition which clears quickly as the flame stabilizes and the refractory heats may be ex- pected with a well adjusted burner. See TM 5-644 for adjustments if ignition is
49、 improper or burner puffs back. If oil does not flow freely, turn off burner and remove and clean oil strainer. If air or oil adjustment 11 TAC30 01B Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-D 3535789 0203594 768 is made, notify the heating supervisor to arrange for adjustment of burner with a flue gas analyzer (AR 420-49). d. Gas Burners.
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