The objective of this Standard Operating Procedure for Cleaning and Preventive Maintenance of Hot Water Generator System is to outline the steps and guidelines for conducting cleaning and preventive maintenance on a Hot Water Generator System to ensure its efficient operation, longevity, and safety.
SOP for Cleaning and Preventive Maintenance of Hot Water Generator System
OBJECTIVE:
To lay down the procedure for cleaning & preventive maintenance of hot water generator system.
SCOPE:
This SOP is applicable to operation of hot water generator installed at technical area.
RESPONSIBILITY:
Technician/ Operator shall be responsible for proper execution of Cleaning and Preventive Maintenance of Hot Water Generator System as per SOP.
Engineering – Head shall be responsible for reviewing the SOP and for ensuring proper execution of Cleaning and Preventive Maintenance of Hot Water Generator System.
ACCOUNTABILITY:
Engineering – Head shall be accountable for the implementation of the SOP for Cleaning and Preventive Maintenance of Hot Water Generator System.
DEFINITIONS:
Nil
PROCEDURE:
Preventive maintenance shall be executed as per the SOP No.: SOP/EN/XXXYYY– Execution of Preventive Maintenance.
Ensure that the spare parts are available at the time of preventive maintenance.
Cleaning and Preventive Maintenance of Hot Water Generator System – Mechanical
Cleaning makeup water tank:
Cleaning of water make up tank to be done on monthly ±5 days.
Close main water inlet valve to the makeup water tank.
Open the drain valve of the tank and left water drain off.
Scrub the internal surface of the tank with the help of brush and allow the water to drain out from the drain point.
Dismantle the strainer filter in the outlet of the sump tank and clean it.
Checking procedure of PHE for any leakage:
Switch off the pump.
Close the inlet and outlet valves of the PHE.
Check the tightness of PHE bolts.
Checking the tightness of plates, wash thoroughly and check for the condition gaskets. If required replace the gaskets.
Refit the plates, tighten the bolts and open the valve check for any leakage and rectify if any.
Checking frequency shall be done at every six month.
Cleaning of pump strainer installed in suction line
Shut down the pumps
Close the isolation valve of pump.
Open the flanges of strainer, remove the mesh; clean and replace if required. Or open the drain plug of strainer and remove the arrested particles in mesh and refit the plug.
Put the mesh inside the strainer, tight the nut and bolts of flanges.
Open the valve.
The cleaning frequency shall be done every month.
Checking of the valves
Check the valves for smooth closing and opening, If the Valves are operating hard Preventive Maintenance of the valves as mentioned Below:
Switch off the pump.
Close the nearby upward and downward side valves.
Open the valve flanges lightly to drain out the water.
After draining the water open the full flanges.
Check the valve steam and valve internals for any damage, for valve seat, gaskets, stem locking
Nut tightness; if required clean or replace the internals.
Refit the valve, open the both side nearby valves, check for any leakages, and check norma
Closing and opening operation. If found Satisfactory, put the system “ON” or otherwise replace valve
The valve checking frequency shall be after every month.
Checking of the steam safety valve
Increase the steam pressure above the set point of safety valve, the safely valve should pop up and steam will come out.
If steam is not come out then verify the set point and recheck the operation of safety valve by increasing steam pressure as by same above point, if found okay, then put it in the system or otherwise replace the same.
The checking of safety valve should be checking once in after six month.
Checking of hot water pipeline and fittings
Check all the pipe line supports and flange joints and tighten them if found loose.
Check the flange joints nut and bolts on pipeline and fittings for leakages. If any leakage is Observed then check the gaskets, if found damaged replace the same and tighten the clamp.
Physically check the gasket if found damage (cut, deform, leached, shape and size change) it should be replaced.
Check the insulation and cladding, if required repair the insulation and cladding.
Checking shall be done on six monthly.
Checking of hot water circulation pump.
Check for any leakages from the mechanical seal, if found rectify the same.
Check the condition of coupling between pump and motor, if found damage replaces the same.
Check the pump for any abnormal sound if found, check the bearing impeller and other moving parts, if found damaged rectifies the same.
Checking shall be done on quarterly basis.
Checking of steam trap
Check the steam trap for condensate flow, leakages and proper functioning.
Checking shall be done on six monthly basis.
Cleaning and Preventive Maintenance of Hot Water Generator System – Electrical
Checking of Terminals, Wiring and Components
Ensure that the power supply to the machine is switched off.
Visually check all the power and control wiring for its tightness if found loose rectify the same
Checking shall be done on quarterly basis.
Checking of motor
Check all connection tightness, if found loose tighten it.
Check the phase continuity and winding continuity of motor with the help of tong tester.
Physically check the motor terminal box and terminal connections.
A good earthing shall show less than 2 Volts between the Neutral Wire of the Incoming Power supply and Panel Body.
Checking shall be done at every six months ±15 days.
Checking of Contactors
Check the functioning of contactor if found any abnormality, rectify the same.
Check the earthing of the panel body.
Check the overheating of conductor it found, rectify the same.
Checking of contactors shall be done on six monthly ±15 days.
Post Cleaning and Preventive Maintenance of Hot Water Generator System – Check List
Record the Preventive Maintenance details as per the Format No.: SOP/EN/XXXYYY “Preventive Maintenance Checklist & Record for Hot Water Generator”.
Whenever any modifications and major works are carried out to the equipment, the same shall be mentioned in the equipment history card as per the respective SOP.
Connect the equipment main power supply and start the equipment.
Ensure that the equipment is running smoothly, without any abnormality.
If any abnormality is observed in the above, same will be attended in co-ordination with User department Head.
ABBREVIATIONS:
CRF No. : Change Request Form number
QA : Quality Assurance
PRV : Pressure Reducing Valve.
PHE : Plate Heat Exchanger.
REFERENCES:
Nil.
DISTRIBUTION LIST:
SOP shall be distributed to following departments Quality Assurance, Engineering as per user request.
ANNEXURES:
Preventive Maintenance Check List & Record for Hot Water Generator: SOP/EN/XXXYYY
Cleaning and Preventive Maintenance of Hot Water Generator System Checklist & Records
Equipment Name
Location
Equipment ID
Frequency
Check List
Check
Remark
Monthly Check List
Cleaning of water make up tank.
Cleaning the strainer installed in suction line of hot water circulation pump.
Checking of the valves for smooth opening and closing.
Quarterly Check
Checking of hot water circulation pump for mechanical seal; motor bearings.
Check the pump for any abnormal sound.
Half Yearly Check List
Checking of plate type heat exchanger.
Checking of steam safety valve.
Checking of hot water pipe line and fittings.
Checking of electrical motor
Checking of contactors.
Check the steam trap for condensate flow, leakages and for proper functioning.
