SOP for Cleaning and Preventive Maintenance of Steam Boiler is to establish a standardized procedure for the cleaning and preventive maintenance of steam boiler, ensuring their safe and efficient operation, reducing the risk of breakdowns, and extending their operational lifespan.
SOP for Cleaning and Preventive Maintenance of Steam Boiler
- OBJECTIVE:
- To lay down the Procedure for cleaning & Preventive Maintenance of Steam Boiler installed in utility area.
- SCOPE:
- This SOP is applicable to cleaning & preventive maintenance of Steam boiler installed in utility area.
- RESPONSIBILITY:
- Technician/ Operator – Engineering shall be responsible for Preventive Maintenance of Steam Boiler.
- Head – Engineering shall be responsible for ensuring compliance of the SOP.
- ACCOUNTABILITY:
- Engineering – Head shall be accountable for proper implementation of the SOP for Preventive Maintenance of Steam Boiler.
- DEFINITIONS:
- SOP for Cleaning and Preventive Maintenance of Steam Boiler: A detailed and standardized set of instructions outlining the step-by-step procedures to be followed for the regular cleaning and preventive maintenance of steam boilers. This SOP aims to ensure the safe and efficient operation of steam boilers by providing guidelines for visual inspections, combustion system checks, safety device testing, cleaning of internal components, water treatment analysis, comprehensive inspections, efficiency testing, and calibration. Adhering to this SOP minimizes the risk of breakdowns, enhances boiler performance, extends its operational lifespan, and maintains the overall integrity of steam boilers used in various industrial processes and heating applications.
- 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 before start of preventive maintenance activity.
Preventive Maintenance of Steam Boiler Schedule and Check List
- Monthly Preventive Maintenance:
- Check steam pressure switch operation.
- Check mobrey level controls for pump on-off operation.
- Clean strainers in feed pump suction line.
- Check safety valve operation.
- Check motor electrical connection for burner, feed pumps, fuel feed pumps and main pumps.
- Clean the boiler smoke tubes.
- Check all relief valves for leakages.
- Check pilot and burner assemblies and examine for mineral or corrosion build up.
- Inspect the boiler air leaks and check the damper seals.
- Inspect all the linkages on combustion air dampers.
- Check the blow down and water treatment procedure. Determine the blow down is accurate to prevent solids build up.
- Check the gasket for tight sealing and replace them if necessary.
- Check hooter operations.
- Check motor interlocks.
- Check the stock of essential spares.
- Clean the furnace.
- Check the electrical contactor contacts.
- Check the burner rod and burner rod assembly.
- Check cleaning of oil filter.
- Checking of photocell.
Quarterly Preventive Maintenance of Steam Boiler:
- Check the feed line check / non return valve.
- Remove the dust from electrical control panel.
- Check front reversal chamber refractory and repair if required.
- Grease all motor’s bearings, if required.
- Check the condition of smoke box sealing rope, if found damage then replace.
Half Yearly Preventive Maintenance of Steam Boiler:
- Clean ‘the electrical panel from outside and inside with air blower.
- Clean the view glass properly.
- Check the feed pump for leakage.
- Clean the strainers, electrode & burner nozzle.
- Check the valves for any leakage.
- Clean the tubes with wire brush.
- Check the tightness of the impeller fans.
- Open the man hole door and check for the scale formation if any scale is observed remove it.
- Clean the mobrey float valve.
- Check refractory for any damage and carry out its repair work if required.
- Clean the chimney and remove carbon.
Yearly Preventive Maintenance of Steam Boiler:
- Carry out all the half yearly check points.
- Inspection of the boiler will be carried out with the government authorities.
Checking of spare parts
- Check the stock of following recommended spare parts
| Sr. No. | Component Description | Quantity (Nos.) |
| 1 | Air break switches for mobrey | 2 |
| 2 | Float rod assembly for mobrey | 1 |
| 3 | Hooter Control Panel | 1 |
| 4 | Indicating Lamp holder | 2 |
| 5 | Indicating Lamps | 12 |
| 6 | Feed Water Pumps | 1 |
| 7 | IBR pressure gauge 10” dial for boiler | 1 |
| 8 | Fusible plug | 2 |
| 9 | Blow down valve IBR | 1 |
| 10 | Non return valves feed line IBR | 1 |
| 11 | Gauges glass assembly IBR | 1 |
| 12 | Gauge glass | 2 |
| 13 | Quick shut off valve size | 1 |
| 13.1 | Burner Spares | |
| 14 | Fuel Pressure gauge | 1 |
| 15 | Burner nozzle as per consumption Kg/ hr | 1 |
| 16 | Sequence controller Siemens | 1 |
| 17 | Photo resister | 1 |
| 18 | Sight glass burner | 2 |
| 19 | View glass rear | 2 |
| 20 | Ignition transformer | 1 |
| 21 | Burner gun | 1 |
| 22 | Pressure switch high pressure cut off | 1 |
| 23 | Proportional pressure controller | 1 |
| 24 | Rectifier | 1 |
| 25 | Burner Diffuser Plate | 1 |
| 26 | Burner Solenoid valve | 1 |
| 27 | Fuel Pump | 1 |
| 28 | Feed back potentio-meter | 1 |
| 29 | Servomotor | 1 |
| 30 | Electrode assembly | 2 |
| 31 | Electrode Cap | 2 |
| 31.1 | Burner Spares | |
| 32 | Gas pressure gauge Range 1 – 10 bar | 1 |
| 33 | Gas pressure gauge range 0 – 100 Mbar | 1 |
| 34 | Main gas pressure regulator range 1 – 4 bar | 1 |
| 35 | Main gas burner solenoid valves | 2 |
| 36 | Gear train assembly for gas regulation | 1 |
| 37 | Pilot burner solenoid valve | 1 |
| 38 | Pressure switch gas pressure high | 1 |
| 39 | Pressure switch gas pressure low | 1 |
| 40 | Diffuser plate | 1 |
| 41 | Sequence controller | 1 |
| 42 | UV cell | 1 |
Preventive Maintenance of Steam Boiler Check List
- Post Preventive Maintenance Check List
- Record the PM details as per the Format No.: SOP/EN/XXXYYY “Preventive Maintenance Checklist & Record for Steam Boiler”.
- 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
- REFERENCES
- Operational & Maintenance Manual of Steam Boiler.
- DISTRIBUTION LIST
SOP shall be distributed to following departments Quality Assurance, Engineering as per user request
- ANNEXURES
- Preventive Maintenance checklist & Record For Steam Boiler: SOP/EN/XXXYYY
Check List & Records Preventive Maintenance of Steam Boiler
CHECKLIST & RECORD
| Equipment Name | Boiler | Location | |
| Equipment ID | Frequency |
| Maintenance activity | Check | Remark |
| Monthly Preventive Maintenance | ||
| Check steam pressure switch operation. | ||
| Check mobrey level controls for pump on-off operation. | ||
| Clean strainers in feed pump suction line. | ||
| Check safety valve operation. | ||
| Check motor current for burner feed pumps______; fuel feed pumps______ and ring main pumps_________. (Set value current) (Observed value for burner feed pumps______; fuel feed pumps______ and ring main pumps_________) | ||
| Clean the boiler smoke tubes. | ||
| Clean the smoke tubes and furnace. | ||
| Check the furnace combustion air chamber is free from leakages. | ||
| Check the electrical contactor contacts. | ||
| Checking of burner and burner rod assembly. | ||
| Cleaning of oil filter. | ||
| Checking of photocell. | ||
| Quarterly Preventive Maintenance | ||
| Check the feed line check / non return valve. | ||
| Remove the dust from electrical control panel. | ||
| Check front reversal chamber refractory and repair if required. | ||
| Grease all motor bearings, if required. | ||
| Check the condition of smoke box sealing rope, if found damage replace | ||
| Half Yearly Preventive Maintenance | ||
| Clean the electrical panel from outside and inside with air blower. | ||
| Clean the view glass properly. | ||
| Check the feed pump for leakages. | ||
| Clean the strainers; electrode and burner nozzle. | ||
| Check the valves for any leakage. | ||
| Clean the tubes with wire brush. | ||
| Check the tightness of the impeller fans. | ||
| Open the man hole door and check for the scale formation if any scale is observed remove it. | ||
| Clean the mobrey float valve. | ||
| Check the refractory for any damage and carry out its repair work if required. | ||
| Clean the chimney and remove carbon. | ||
| Yearly Preventive Maintenance | ||
| Check out all the half year check points. | ||
| Inspection of boiler will be carried out with the government authorities. | ||
| Open the man hole cover and cleaned in side with wire brush. | ||
| Check for the safety instrument operation. |
You may also read about Good Laboratory Practices (GLP)