Follow
Objective: To establish a standard preventive maintenance procedure for Boiler.
Scope: This SOP is applicable for the preventive maintenance of Boilers (Cleaver Brookes, Model: CIW-700-200-150 & CIW-700-125-150) installed at the utility building of (Company Name).
Responsibility
1 Operator shall be responsible to follow the procedure strictly.
2 Supervisor shall be responsible to ensure that the SOP is followed properly.
Accountibility Manager, Engineering.
Precautions
1 Concerned personnel should be trained on the SOP.
2 Before starting the maintenance work, stop the Boiler and isolate the power supply. Depressurize the system. Hang the board “UNDER MAINTENANCE”.
Procedure
6.1 The preventive maintenance of Boiler consists of weekly, monthly & yearly maintenance. Carry out the maintenance work as per the Maintenance Check List shown in ANNEXURE-I. The format annexed is of duration of 6 months. For the use of subsequent period of different durations, the same format with appropriate month and year to be printed in the format. This printed format will be a controlled copy issued by Q.A.
6.2 WEEKLY maintenance:
6.2.1 Clean the air inlet damper.
6.2.2 Clean the blower motor.
6.3 MONTHLY maintenance:
6.3.1 Check for proper operation of Gas line valves & regulators.
6.3.2 Check gas leakages from the pipeline.
6.3.3 Check that the indicating lights are glowing properly and alarms are indicated.
6.3.4 Check the control panel for flame safeguard controller and selector switch.
6.3.5 Check pressure controller, modulating controller, High–Low Fire controller & limit controllers for proper setting & operation.
6.3.6 Check for leaks, noise, vibration and unusual conditions.
6.3.7 Check that the burner is working properly.
6.3.8 Check the cams for wear or dislocation.
6.3.9 Check and confirm safety and interlock controls.
6.3.10 Analyze combustion ratio. The smoke from the chimney exhaust should be white, not black. Clean the chimney top end externally.
6.3.11 Check the stack thermometer gauge for proper installation & reading.
6.3.12 Clean the low water cut off.
6.3.13 Clean the air cleaner.
6.3.14 Check the refractory.
6.3.15 Check the level switch & sight glass tube of feed water tank for proper operation & visibility.
6.3.16 Check the water softener for proper functioning.
6.3.17 Check the motors for free rotation, cable termination & insulation.
6.3.18 Check the external insulation for damages or burn out. If found rectify it.
6.4 YEARLY maintenance:
6.4.1 Open the access door & clean the fire chamber & tube surface with wire brush.
6.4.2 Check the waterside surface. If any scale formation is found, clean the surface mechanically / chemically.
6.4.3 Check operation of safety valves.
6.4.4 Check the condition of feed water pumps. Change the gaskets of the pump connection.
6.4.5 Check the gasket of doors, valves, chimney flanges, motor and blower. If found damaged then replace with correct type of gasket.
6.4.6 Carry out the hydraulic test.
6.4.7 Clean the Stack & chimney internally thoroughly.
6.4.8 Check the water pretreatment system. Check the condition of vessels, pipelines, fittings & valves. Check for leakages. If found rectify it.
6.4.9 Check the condition of resins. If it is discolored or light in weight then replace the resins.
6.5 After completion of maintenance work, clean the surrounding area of the machine. Remove the dirt and clean by dry cloth. Check that no objects or tools are left in or around the machine.
6.6 Record the description of work and spare parts used (if any) in FRM No.: FEG/007-00.
