Boiler, Purpose:
Boiler, The purpose of this SOP is to define the standard operation and maintenance procedure of Boiler in order to ensure its smooth & trouble-free operation and generation of steam.
Boiler, Scope:
This SOP is applicable to Cochran Diesel / Gas Boiler which is located at the ground floor of Sterile Block of XX Pharmaceuticals Ltd.
Definitions / Abbreviation:
[][]Boiler: A boiler is a closed vessel in which water is heated; steam is generated and superheated from any combination of heat from combustible fuels or electricity.
[][]EHS: Environment Health and Safety.
[][]PPE: Personal Protective Equipment.
[][]SOP: Standard Operating Procedure.
[][]TDS: Total Dissolved Solids.
Responsibilities:
[][]The roles and responsibilities are as follows:
Validation (Engineering) Department
[][]Preparing the SOP and revise it when necessary.
Engineering Department
[][]To provide necessary support for smooth operation & maintenance of boiler.
[][]To ensure that the operators are responsible to carry out the operation and maintenance work and regular checking of critical components and logbooks.
[][]To develop a list of spare parts based on the manufacturer’s recommendations and to forward the list to the Planning and Procurement department with a request to place order as required.
Operators
[][]To operate the Boiler according to the SOP.
[][]To fill up the logbooks related to the Boiler.
[][]To do the maintenance according to the check list.
Manager, Engineering
[][]To ensure that the operation and maintenance of the Boiler.
[][]To approve any maintenance/plans related to the Boiler.
Manager, Quality Assurance
[][]To ensure overall implementation of this SOP.
Procedure:
Precautions:
[][]All operation and maintenance work must be done safely in accordance with the requirements of the Plant Safety Statement and the safety notices around the plant. Specific attention must be paid to the following:
[][]Personal protective equipment (PPE) and clothing appropriate to the job must be worn.
[][]Ensure the control panel is switched off before carrying out any maintenance.
[][]Maintenance activity must be carried out by trained technician/operators.
[][]No unauthorized person is allowed to do any kind of operation or maintenance to the boiler.
[][]The cover doors must be kept closed during operation.
[][]The safety mechanism of the machine must be checked by the operator for reliability in each and every working day.
[][]“Under Maintenance” be displayed in a prominent position on a machine, equipment or facility undergoing maintenance work.
Pre-start Check
[][]To ensure the permanent ventilation of the boiler house (Excluding doors and windows) is capable of supplying sufficient air for combustion and to keep the boiler house cool.
[][]Check all mechanical connections are properly tightened and have not worked loose in transit.
[][]Check direction of rotation of burner fan motor.
[][]To ensure oil / Gas is present.
[][]To ensure fuel / Gas valve is “OPEN”.
[][]To ensure water level in the feed water tank is enough.
[][]To ensure the burner switch on the control panel is OFF.
[][]To ensure feed water pump valve is “OPEN”
[][]To ensure that the fuel / Gas selector switch has selected OIL.
[][]To ensure that the gas isolating valves are closed and the oil isolating valves are open.
[][]The boiler feed pump should be filled with water on its suction side.
[][]The boiler should be filled with softened water.
[][]Ensure the fuel / Gas filters are clean.
Starting Procedure
[][]Main switch turn to “ON” position.
[][]Switch on the feed water pump selector switch (No.1 or No.2 for respective pump selection).
[][]Turn feed water pump control switch to “AUTO” position from “OFF” position.
[][]Turn burner control switch to “LOW” position from “OFF” position.
[][]When boiler steam pressure reaches up to (6.5-7) bar then turn burner control switch to “LOW” position from “OFF” position.
During Operation
[][]All boiler gaskets, valve stuffing boxes and valve gaskets are to be checked periodically during the boiler heat-up.
[][]The boiler pressure gauge should be observed during this heat-up period.
[][]Water analysis after every 12 hours of operation. If feed water is found to be hard any time, stop the boiler immediately. Drain the water from the service tank.
[][]Regenerate the softener and fill up the feed water tank then restart the boiler.
[][]Any excessive sound coming from motors or any moving part.
[][]All valves, joints, head-hole and manhole covers are leak tight.
[][]The water level is correct and steady.
[][]Steady steam pressure is maintained.
[][]Check Safety valve.
[][]Check fuel pressure.
[][] The Operational Log Sheet (Annexure – I) of boiler will be filled up on every hour by the operator. Photocopy of all the approved forms will be used where easily applicable. For the cases where computer generated copies are relatively easy to handle, the exact format of the approved form can be used(except the approval sign) with the following notes as footer:
“This is a computer generated report. The format is as per the original approved form.”
Boiler Stopping Procedure
[][]Turn burner control switch to “OFF” position.
[][]Turn feed water pump control switch to “OFF” position.
[][]Fuel / Gas valve is off.
[][]In case of an emergency where immediate shutdown is necessary, the emergency stop push button should be pushed immediately.
Preventive Maintenance Planning
[][]During maintenance works the equipment must be electrically isolated. After performing maintenance works maintenance log book (as same as Annexure – II) has to be filled up by the operator. The schedule which follows must be applied at the Interval which occurs first.
Daily Maintenance
[][]Ensure that the fuel filters are clean.
[][]Check the water level.
[][]Clean the viewing glass
[][]Check the operating pressures.
[][]The boiler feed pump should be filled with water on its suction side.
[][]The boiler should be filled with softened water.
[][]Check the quality of feed water.
[][]Check the safety valve.
Weekly Maintenance
[][]Clean the flame sensor & viewing glasses.
[][]Check the water level is properly controlled.
[][]Check the low level & extra low level alarms by reducing the water level.
Monthly Maintenance
[][]Clean igniter assembly.
[][]Drain the feed water tank to remove the sediment.
[][]Clean the burner nozzle & ignition electrodes.
[][]Check oil / Gas leaks.
Quarterly Maintenance
[][]Clean electrical contacts of all relays & tighten loose connection if any.
[][]Check the water pump seal non-return valve.
[][]Check & clean the furnace if required.
[][]Service burner unit.
[][]Check door and furnace seals.
[][]Visual check of refractory’s.
[][]Check control panel.
[][]Set-up combustion.
[][]Check safety interlocks.
[][]Drain & clean the water service tank.
[][]Check the feed water pump.
[][]Check the seals of the feed water pump.
[][]Clean the blower fan blades
Half Yearly Maintenance
[][]Check the valves for leakages; lap them if found leakage.
[][]Lubricate the bearing of water pump.
[][]Check the sealing of Manhole, head holes & clean out door of smoke box.
Annually Maintenance
[][]Check the burner position, adjust if required.
[][]Clean the boiler tubes with brush.
[][]Clean the combustion chamber.
[][]Overhaul the valves.
[][]Check the door refractory for any damage, repair if necessary.
[][]Check the door seal to make sure that there is no gas leakage.
[][]Clean the water side of the boiler thoroughly.
Annexure:
Annexure – I: Operational Log sheet of Boiler.
Annexure – II: Maintenance Log sheet of Boiler.