BOILER

1.0 PURPOSE

It is established to ensure require supply of steam pressure and temperature used in different departments of production.

2.0 SCOPE

It is applicable in every production department wherever the steam is required accordingly.

3.0 RESPONSIBILITY

Boiler Engineer (B Class & C Class)

Maintenance officer (Mechanical / Electrical)

Maintenance Supervisor (Mechanical / Electrical)

4.0 PROCEDURE

The Boiler with instrument is handled in the following way.

4.1 CLEANING:

Clean the boiler and tools with clean cloth to remove dust.

Clean the boiler or annually basis: i.e.

Shut down the boiler for annual cleaning & inspection.

Fill the boiler with water and add, “de-scaler” in it.

Circulate this “de-scaler” added water for 24 hours in the boiler to remove scaling.

After completing this de-scaling procedure drain that water.

Wash the boiler from inside with fresh water to drain out all impurities of the boiler.

Open the different parts of boiler i.e.

Steam drum.

Water drum.

Safety Valve.

Air Ventilation valve.

Main stop valve.

Water gauge glass.

Water/steam pressure headers etc. including all fitting and mountings.

After this step internal & external cleaning and maintenance of the whole boiler parts will be taken place.

After maintaining all the parts according to the specifications now the boiler is ready for the annual inspection (inspected by a boiler inspector).

Make a coat of Epexier paint to protect the boiler from scaling.

After assembling of all fitting, mounting etc test the boiler with hydraulic pressure to check the leakage in tubes valves, joints etc.

Now the boiler is ready for the operations.

The boiler operators/section Incharge will maintain machinery/equipment cleaning logbook.

4.2 STARTUP & OPERATION:

Check the water level in boiler and “main feed water supply tank”.

Check the feed water pumps.

Switch to “ON” the main electric power supply.

Open the forced and induced draught dampers.

Open the main natural gas valve.

Start up the forced draught fan and purch the boiler for 5 minutes for the ventilation of un burnt gases from boiler furnace.

Open the air ventilation valve of steam drum.

Switch OFF the forced draught fan close dampers then fully open the chimney damper.

Light up the poilet burner with torch.

Light up the main burner to maintain the required steam pressure.

After maintaining the required steam pressure release the steam for the different production departments.

In case of natural gas load shedding boiler is operated on furnace oil.

5.0 MAINTENANCE

5.1 MONITORING OF MACHINE MAINTENANCE:

Time to time check each and every part of Boiler according to the maintenance schedule.

Check the following parts carefully.

vBlower motor

vElectric Starter

vV, Belt

vSteam Valve

vDosing pump

This activity is then documented in the form Machinery & Equipment Maintenance Log

Check the Boiler condition time to time to find any kind of problem during operation.

All the monitoring record is filed and kept by the Maintenance Supervisor.

5.2 EMERGENCY / BREAKDOWN MONITORING:

Maintenance Manager receives Maintenance Work Order duly signed by the section incharge of the concerned machinery or equipment.

Maintenance Work Order is assigned a number according to the receiving in the Maintenance Reference Register.

Maintenance Manager assigns the maintenance work to the concerned personal

After the completion of work the section incharge signs the completion of Work Order.

All the record is filed and kept by the Maintenance Supervisor.

6.0 PRECAUTIONS:

The pressure should be maintained slowly to the desired pressure through out the process.

Slowly release the steam to avoid the steam hammering in the steam lines.

Maintain the water level before light up the boiler and during operation.

Check the boiler’s safety valves time to time; it must be in a proper working condition.

Blow off the water gauge glass. Once a shift to check their normal working condition.

Blow off the main blow down of boiler in every shift to avoid scaling in the boiler.

User desired quantity of boiler chemical to avoid scaling.

Do not try to light the boiler with out perching or direct main valve flame to avoid furnace explosion.

Ensuring that the exposure door is working properly.