The objective of this (Standard Operating Procedure) SOP for preventive maintenance of Pure Steam Generator is to outline the steps and guidelines for conducting preventive maintenance on the Pure Steam Generator to ensure its optimal performance, reliability, and compliance with regulatory requirements.
This SOP is describing the Preventive Maintenance of Pure Steam Generator.
SCOPE:
This SOP is applicable for Preventive Maintenance of Pure Steam Generator, installed in PSG room at technical area .
RESPONSIBILITY:
Technician/ Operator shall be responsible for the 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
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.
Ensure that the spare parts are available at the time of preventive maintenance.
Preventive Maintenance – Mechanical
Checking of pipeline and fittings
Physically check all the pipe line supports and clamps and tighten them if found loose.
Physically check the tri-clover clamps on pipeline and fittings for leakages. If any leakage is present then physically check the silicon gaskets, if found damaged (cut, deform, leached, shape changed) replace the same and tighten the clamp.
Checking shall be done monthly.
In Preventive Maintenance of Pure Steam Generator :Checking of Diaphragm Valve
Check the valve for smoothly movements, if the operating hand wheel of valve is found jam med or stuck, then open the valve and carry out the maintenance as follows.
Switch of the pump.
Close the nearby upside and down side valves
Open the TC ends, loose the diaphragm valves nut by the Allen key, check the valve for damaged diaphragm, clean the valves, and check for the locking nut of diaphragm.
If gasket found damaged (cut, leached, deform, shape and size change) change the diaphragm.
After physically checking of diaphragm valve, refit in to the system and check for leakage and valve operation if found satisfactorily then it is okay otherwise replace the valve
.For actuated diaphragm valve check for the performance of actuator for valve opening and closing as per interlocks of the system
Checking of valve shall be done monthly
Checking of evaporator and condenser column
Visually inspect the evaporator and condenser internally for surface roughness, crashes, cleanliness, damage, and dent and rusting; if found clean thoroughly and rectify the same.
Physically check and inspect the evaporator and condenser insulation and cladding, if required repair.
Physically check the end connection to evaporator and condenser for leakages, if required rectifies the same.
Physically check the evaporator and condenser installed instruments such as level transmitter, compound pressure gauge for proper functioning, if required remove, clean and refit the same or if necessary replace the same.
Checking of evaporator and condenser column shall be done after every six month.
Checking for the steam trap
Check the steam trap for condensate flow; remove the sediment or dust arrested in the strainer.
Checking of the steam trap shall be done quarterly.
Checking for the steam inlet valve
Check the steam inlet valve for the smoothly closing and opening of valves; if it jammed; then carry out the maintenance as follows
Close the isolation valve of steam line.
Open the valve by loosening the flange nut bolts.
Check for the gasket; valve seat stem locking nut; clean and refit the same; if required replace the gasket if it get damaged.
Refit the valve and check for any leakage and proper working; if required replace the valve with new one.
Checking of the steam valve shall be done after six month
Checking of the steam safety valve
Increase the steam safety valve above the set point, the safely valve should pop up and steam will come out.
If steam is not come out then check the set point. Recheck the operation of safety valve 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 blow down of system
Check the blow down timing it should be as per recommendation of manufacturer.
Checking of blow down shall be done monthly.
Checking of NCGR tank
Visually inspect the tank internally for surface roughness, crashes, and cleanliness, damaged, and dent and rusting; if found clean thoroughly and rectify the same.
Physically check and inspect the tank insulation and cladding, if required repair.
Physically check the end connection to tank for leakages, if required rectifies the same.
Physically check the tank installed instruments such as level transmitter, compound pressure gauge for proper functioning, if required remove, clean and refit the same or if necessary replace the same.
Checking frequency shall be done monthly.
Checking of sample cooler
Physically check the sample cooler for any leakage if found rectify the same.
Checking of sample cooler shall be done after every six month.
Checking of feed pump
Physically check the feed pump for any abnormal noise if found, Disconnect the pump motor wiring
Disconnect the pump from the pipeline and open the pump.
Physically check the condition of bearings, mechanical seal, shaft, impeller and replace if found damaged.
Checking of the pumps shall be done quarterly.
In Preventive Maintenance of Pure Steam Generator Descaling of Pure Steam separator / Evaporator
CONCENTRATION : 2% of total volume of water. ( In liter )
CIRCULATION TIME : Two hours for each chemical
EQUIPMENT FOR CIRCULAION : S.S. Circulation Pump I Phase capacity:- 400- 500 liter/ hr., Hose Pipe with TC connection Suitable For Acids ,tank for Preparation of solution.
Safety Precautions
Isolate all Sensor from pipe and put The Blind plugs, Isolate the Pure steam Out let line .
Rubber or PVC gloves , Eye goggles & aprons should be provided to the workers during preparing the solution
Procedure:
In 300 Liters surge tank & fill up with Purified Water with connecting circulation pump.
Evaporator Tube Side and Separator:
Disconnect the pipe from Rota-meter outlet & connect the circulation pump outlet pipe to this line. Closed the pure steam outlet isolation valve
Connect the return line to sampling point line & put in the surge tank.
Fill up 250 liter Purified Water in the surge tank. Start the circulation pump of surge tank. & keep filling surge tank once again with Purified Water & maintain it 250 liter in the surge tank till the Purified Water return from the sampling point line & it will drop inside the surge tank.
Stop the circulation pump of surge tank.
Dilute 5% of caustic soda of total Purified Water volume. & Circulate for 2 Hrs.
Maintain the 250 liter Purified Water temperature at 60°C -70°C in the surge tank, by switching ON/OFF steam in valve through the manual operation box for 2 Hrs.
Drain out all the solution from the surge tank. As well as from the column. Flush out the same with hot Purified Water.
Rinse the entire column with fresh water after each chemical process.
Repeat the Descaling processs ( Point no. 6.4.3.2.5 to 6.3.2.8) for each chemical.
Follow the same procedure for below acids
Sulphonic Acid : 1 hour
Nitric Acid : 1 hour
Start the PSG & put it on for 30 min for stabilization.
Inform the QC department through inter office communication and collect the rinse sample for checking of residues of sulphonic acid/ HCL and Caustic Soda.
Once the water is free from the residues then pure Steam can be used for the process.
Descaling Frequency of PSG shall be done once in 2 years during the sanitization activity.
Evaporator Shell Side:
Take one 300 Liters surge tank & fill up with purified water with connecting circulation pump.
Disconnect Plant steam inlet & condensate line.
Connect Pump outlet to columns condensate outlet line.
Connect return line from plant steam inlet point (hose Pipe) back to surge tank.
Fill up 250 liter Purified Water in the surge tank. & dilute 5% of caustic soda of total Purified Water volume. & Circulate for 2 Hrs.
After that drain out all the solution from H/E & surge tank. Flush out the same with hot Purified Water
Rinse the Entire column with Fresh water.
Repeat the Descaling process ( Point no. 6.4.4.5 to 6.4.4.7) for each chemical.
Follow the same procedure for below acids
Sulphonic Acid : 1 hour
Nitric Acid : 1 hour
Rinse entire system with fresh Purified Water for 30 minutes.
Descaling Frequency of PSG shall be done once in 2 years during the sanitization activity.
Checking of instruments
Ensure that the installed instruments are calibrated.
Check the end connection and wiring contact if required tight the same..
Checking of instruments shall be done monthly.
Checking of printer
Check the printer for paper alignment and printer cartridge ribbon.
Checking of printer frequency shall be done after every six month.
Common faults and remedial actionin Preventive Maintenance of Pure Steam Generator
SR.NO.
FAULT
REMEDY
1.
Steam pressure does not increase
Check incoming steam supply.
Check steam trap.
Check PRV.
Check choke up in condensate line.
Check float sensor.
2.
Purified water does not flow from evaporator to separator
Clean the washer inside the pipe lines if it is clogged.
3.
Complete plant not starting
Check conductivity of incoming feed water.
Check conductivity probe of purified water inlet.
Check incoming three phase. Supply.
Check fuse links of incoming supply.
Check overload relay reset if it is tripped.
Check compressed air pressure.
In Preventive Maintenance of Pure Steam Generator, Check the stock of following recommended spare part
Check the stock of recommended spare part list on quarterly
SR. NO.
DESCRIPTION
QUANTITY
1.
SOLENOID VALVES
2 NOS
2.
STEAM TRAP
1 NO
3.
DEMISTER PAD
1 NO
4.
INDICATION LAMP
2 NOS
5.
DOSING PUMP SPARES KIT
2 NOS
6.
PNEUMATIC DIAPHRAGM TYPE VALVE
2 NOS
7.
MANUAL DIAPHRAGM VALVE
2 NOS
8.
PNEUMATIC PISTON TYPE VALVE
2 NOS
9.
MANUAL BALL VALVES
2 NOS
Checking of tank (NCGR), Evaporator and Separator (columns) and pipelines for any rouging
Check the tank (NCGR), Evaporator and Separator (columns) and pipelines for any rouging.If found, clean the surface of tank /columns and pipelines with buffing or electro polishing process.
Checking shall be done after every six month.
Preventive Maintenance of Pure Steam Generator – Electrical
Checking of terminals and wiring
Ensure that the power supply to the panel is switched off.
Visually check all the power and control wiring and terminals in the electric control panel and at field instruments.
Check and ensure by using screwdriver that all the wires are properly tightened.
Checking shall be done six monthly.
Checking of contactors
Switch off the main switch on the electrical panel.
Disconnect all the control and power wires from the contactor terminals.
Remove the dust from control panel with help of air blower.
Remove the contactor from the panel and visually check all the contacts for pitting and carbon deposits on the contacts.
Clean all the contacts with carbon tetra chloride or with contactor cleaner. Replace the contacts if found damaged or welded.
Put back the contactor in the panel and connect all the wires to the original locations.
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 six monthly.
Checking of motor of centrifugal type distribution pump
Check the insulation resistance of motor winding with the help of megger.
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.
In Preventive Maintenance of Pure Steam GeneratorChecking of VFD terminals
Switch off the main switch on the electrical panel.
Check all the contacts and clean with carbon tetra chloride or with contactor cleaner.
Checking of VFD contacts shall be done six monthly.
Checking of PLC
Check the PLC for blinking of LED.
Check the display
Check the wiring contacts, if required tight the same.
Checking of PLC shall be done after every six month.
Post Preventive Maintenance – Check List
Record the Preventive Maintenance details as per the Format No.: SOP/EN/XXXYYY “Preventive Maintenance Checklist & Record for Pure Steam 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
MMI : Man Machine Interface
LED : Light Emitting Diode
NCGR : Non Condensable Gas Remover
VFD : Variable Frequency Drive
PLC : Programmable Logical Controller
SOP : Standard operating procedure
PSG : Pure Steam Generator
TC : Tri clover
REFERENCES:
Operational & Maintenance Manual of Pure Steam Generator
DISTRIBUTION LIST:
SOP shall be distributed to following departments Quality Assurance, Engineering as per user request.
ANNEXURES:
Preventive maintenance checklist and record for Pure Steam Generator : SOP/EN/XXXYYY
Preventive Maintenance of Pure Steam Generator Checklist & Records
Equipment Name
Location
Equipment ID
Frequency
Things to be done:
Check List
Remarks
Monthly Check List
Checking of pipe line and pipe fittings for any leakages and clamp tightening etc.
Checking of diaphragm valve.
Checking of NCGR tank
Check the installed instruments for proper installation and wiring contacts if required tight the same.
Check the blow down timing of the system
Quarterly Check List
Checking of feed pump.
Check the stock of recommended spare part.
Checking of steam trap.
Half Yearly Check List
Checking of evaporator and condenser.
Checking of sample cooler.
Checking of functioning of steam safety valve.
Checking of main steam inlet valve
Checking of printer.
Checking of VFD terminals.
Checking of electrical motors.
Checking of terminals and wiring.
Checking of contactors.
Checking of PLC.
19. Checking of tank (NCGR), Evaporator and Separator (columns) and pipelines for any rouging. If found, clean the surface of tank /columns and pipelines with buffing or electro polishing process.
Sop for Preventive Maintenance of Pure Steam Generator
