sop for Preventive Maintenance of Boiler

Objective
1.0
To lay down a procedure for Preventive Maintenance of Boiler.
2.0 Scope
This Standard Operating Procedure is applicable for Preventive Maintenance of Boiler (Make – J. N. Marshall to be followed at formulation plants
3.0 Responsibility
3.1 Officer / Executive Engineering shall be responsible for the execution of this procedure
3.2 Engineering Manager shall be responsible for the implementation of this SOP.
3.3 Head QA/designee shall be responsible for the compliance of this SOP.
4.0 Abbreviations and Definitions
SOP : Standard Operating Procedure etc
No : Number
QA : Quality assurance
ER : Engineering
5.0 Procedure
5.1 General Conditions
5.1.1 Refer the master plan of preventive maintenance.
5.1.2 Equipment shall be available for preventive maintenance.
5.1.3 Clean oil / grease stains & remove unwanted material, spares after completion of work.
5.2 Precautions
5.2.1 Use necessary safety wears, while doing the work.
5.2.2 Ensure covers & guards are properly fixed.
5.3 Procedure for preventive maintenance of boiler
5.3.1 Ensure that electrical supply is in off position in main panel and display “Under Maintenance” Board on the panel board.
5.3.2 Switch OFF the drive unit and inform all the concerned.
5.3.3 Operator or above has to ensure and verify the check points for the preventive maintenance as shown in the Annexure – 1, 2&3.
5.3.4 After the completion of preventive maintenance, check the machine for smooth operation.
5.3.5 Remove “Under Maintenance” Board on the panel board after completion of the Maintenance.
5.3.6 The operator / technician who perform the job will enter his name/sign in “Done By” Column and responsible Engineer/ Officer will put sign in “Checked by” column Department head will review the record every month.
5.3.7 Quarterly maintenance will include the jobs of monthly maintenance, half yearly Maintenance will include the jobs of monthly and quarterly maintenance and yearly Maintenance will include the jobs of monthly, quarterly, half yearly and Yearly Maintenance.
5.4 Quarterly preventive maintenance is to be carried out as per the following check points:
5.4.1 Check the foundation bolts of all components (Pumps, Blower, and Motors).
5.4.2 Check the pressure switches for proper operation.
5.4.3 Check all controllers for proper operation.
5.4.4 Clean the Fuel & water line strainers.
5.4.5 Clean the panel and check the tightness of all the terminals.
5.4.6 Clean the burner assembly.
5.4.7 Check the fuel pump coupling & alignment.
5.4.8 Check the proper earthing of electrical devices in machine.
5.4.9 Check all valves for proper operation, if any leakages are observed replace with new one.
5.4.10 Check all gaskets for any leakages, if any leakages are observed rectify by replacing with new gasket.
5.4.11 Carry out all monthly checks as per above.
5.5 Half Yearly Preventive Maintenance is to be carried out as per the following check points:
5.5.1 Check all electrical connections (control panel, all motors,) for any loose connections, burned contacts, signs of overheated wires.
5.5.2 Carry out all Quarterly checks as per above.
5.6 Yearly Preventive Maintenance is to be carried out as per the following check points:
5.6.1 Clean the chimney by opening the inspection cover and its ducting.
5.6.2 Check combustion chamber.

5.6.3 Do the complete over hauling of feed water pump.
5.6.4 Check the pressure switches for proper operation.
5.6.5 Clean the contractors and other switching devices in panel.
6.0 Forms and Records
6.1 Quarterly Preventive Maintenance check list of Boiler Annexure – 1
6.2 Half Yearly Preventive Maintenance check list of Boiler Annexure – 2
6.3 Yearly Preventive Maintenance check list of Boiler Annexure – 3

sop for Preventive Maintenance of Boiler

sop for Execution of Preventive Maintenance

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