The objective of this Standard Operating Procedure preventive maintenance of Boiler Scrubber is to outline the steps and guidelines for conducting preventive maintenance on a boiler scrubber to ensure its optimal performance, compliance with environmental regulations, and safe operation.
SOP for Preventive Maintenance of Boiler Scrubber
- OBJECTIVE:
- To lay down the procedure for preventive maintenance of Boiler Scrubber installed in utility area.
- SCOPE:
- This SOP is applicable to preventive maintenance of Boiler Scrubber installed in utility area.
- RESPONSIBILITY:
- Technician/ Operator / Engineer shall be responsible for proper execution of preventive maintenance as per SOP.
- Engineering – Head shall be responsible for reviewing the SOP and for ensuring proper execution of preventive maintenance of Boiler Scrubber.
- ACCOUNTABILITY:
- Engineering – Head shall be accountable for proper implementation of the SOP.
- DEFINITIONS:
- Nil
- PROCEDURE:
- Preventive maintenance shall be executed as per the SOP No.: SOP/EN/XXXYYY – Execution of preventive maintenance of Boiler Scrubber.
- Ensure that the spare parts are available at the time of preventive maintenance of Boiler Scrubber.
- Preventive maintenance of Boiler Scrubber – Mechanical
- Clean strainers in water circulation pump
- Switch off the water circulation pump.
- Close the isolation valve of pump.
- Open the flanges of strainer, remove the mesh; clean and replace if required.
- Put the mesh inside the strainer, tight the nut and bolts of flanges.
- Open the valve.
- Cleaning frequency of strainer shall be after every month ± 5 days.
- Check the operation of damper valve
- Check and clean the flue gas duct damper valve; it should be easily closed and opened.
- If the closing and opening movement is not properly, then open the damper valve.
- Check for the gasket; if found damaged, cut, deform size and shape change then replace the gasket.
- The checking of damper valve shall be after every three months ± 7 days.
- Lubrication of motor bearings
- Lubricate the pump and blower motor bearings with recommended lubricating grease.
- The lubrication shall be done after every three months.
- Check and clean the sprinkler nozzle
- Check and clean the water sprinkler nozzle for proper water distribution.
- Check the nozzles for tight connections and any leakages if required tighten the same.
- Check and clean the flow strainer.
- Check and inspect the flow pattern, so as there will not be weeping in the packed column.
- Checking of nozzles shall be done after every six month ± 15 days.
- Check of duct work
- Check and clean the flue gas duct.
- Check the end connection of flue gas duct; if required tightens the same.
- Check and inspect the duct for any damage and deterioration.
- Check the chimney for erosion and plugging.
- Checking shall be done after every six month ± 15 days.
- Checking and cleaning of the packed column
- Check and inspect the any leakage; check for the tightness of end connections if required tight the same.
- Check the gasket for damaged; cutting, deformation, leaching if required replace the same.
- Clean the packing media, thoroughly cleaning with water.
- Check the condition of media rings; inspect the packing for damage and settling if required replace the same.
- Check the water re-circulation tank for sediment deposition; if required wash thoroughly form inside and flush out the dust.
- Check the support strength and fasteners, if required tight the same.
- Checking shall be done once in a year ± 30 days.
- Check the nozzles for tight connections and any leakages if required tighten the same.
- Check and clean the flow strainer.
- Preventive maintenance of Boiler Scrubber – Electrical
- Checking of Terminals and Wiring
- Ensure that the power supply to the machine is switched off.
- Visually check all the power and control wiring and terminals in the electric panel and on the field instruments.
- Check and ensure by using screwdriver that all the wires are properly tightened.
- Checking shall be done monthly ± 5 days.
- Checking of motor
- Physically check the insulation resistance of motor winding with the help of meagger.
- Check the phase continuity and winding continuity of motor with the help of tong tester.
- Physically check the motor terminal box and terminal connections.
- Check the voltage drawn by motor with the help of multimeter.
- Check the current drawn by motor with the help of tong tester.
- Physically check the direction of rotation; it should be as per recommended direction.
- Checking shall be done after every six month ± 15 days.
- Checking of Contactors
- Switch off the main switch on the electrical panel.
- Remove all wires from the contactor.
- Remove the contactor from the panel and visually check all the contacts for pitting and carbon deposits on the contacts.
- Remove the dust from control panel with help of air blower.
- Clean all the contacts with carbon tetra chloride (CTC) or with contactor cleaner.
- Replace the contacts if found damaged or welded.
- Put back the contactor in the panel and connect the wires in their respective panels.
- Check the earthing of the panel body.
- A good earthing shall show less than 2 Volts between the Neutral Wire of the Incoming Power supply and Panel Body.
- Checking of contactors shall be done after every six month ± 15 days.
- Post Preventive maintenance of Boiler Scrubber – Check List
- Record the Preventive Maintenance details as per the Format No.: SOP/EN/XXXYYY“Preventive Maintenance Checklist & Record for Boiler Scrubber”.
- 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
- EN : Engineering
- REFERENCES:
- Execution of Preventive Maintenance : SOP/EN/XXXYYY
- DISTRIBUTION LIST:
- SOP shall be distributed to following departments Quality Assurance, Engineering as per user request.
- ANNEXURES
- Preventive Maintenance Record for Boiler Scrubber System : SOP/EN/XXXYYY
Check List and Records for the Preventive Maintenance of Boiler Scrubber
| Equipment Name | Location | ||
| Equipment ID | Frequency |
| Things to be done: | Check List | Remarks |
| Monthly check list | ||
| Checking of terminals and wiring. | ||
| Cleaning of strainer installed in suction line of pump. | ||
| Quarterly Check List | ||
| Checking of operation of damper valve. | ||
| Half Yearly Check List | ||
| Check and clean of the sprinkler nozzles. | ||
| Check of duct work for erosion and plugging. | ||
| Checking of electrical motors. | ||
| Checking of contactors. | ||
| Yearly Check List | ||
| Checking and cleaning of the packed column. |
You may also read about Good Laboratory Practices (GLP)