sop for Operation of Boiler
To lay down a procedure for Operation of Boiler
This Standard Operating Procedure is applicable for Operation of Boiler (Make: Forbes Marshall, Capacity 4500 Kg/hr) to be followed at formulation plants
3.1 Engineering Officer / Executive 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
QA : Quality assurance
Ppm : Parts per million
kg/cm² : Kilo grams per Centimeter square
°C : Degree Celsius
ER : Engineering
TDS : Total Dissolved Solid
NMT : Not More Than
FO : Furnace oil
MCB : Miniature circuit Breaker
MCCB : Miniature Control circuit Breaker
HSD : High Speed Diesel
5.1 Operation of boiler shall be carried out as per the requirement.
5.2 Boiler start and stop operation shall be performed as per the instruction from engineering Officer.
5.3 Operation of boiler:
5.3.1 Boiler can be operated with both FO and Diesel
5.3.2 Check the feed water quality. It shall be as follows.
188.8.131.52 Hardness – Less than5 PPM.
184.108.40.206 PH – Between 8.0 to 9.0
220.127.116.11 TDS- NMT 300PPM for feed water
18.104.22.168 TDS- NMT 3500 PPM For boiler blow down water
5.4 Operation Using FO
5.4.1 Check the level of boiler feed water tank and furnace oil day tank. Level shall be maintained above half level of the tank capacity in both feed water tank and furnace oil in Day Tank.
5.4.2 Open the outlet valve of boiler feed water tank and Furnace oil day tank.
5.4.3 Switch on MCCB, mounted on Boiler main panel & Switch on the MCB of Furnace oil day tank heater from boiler main panel.
5.4.4 FO day tank temperature should be in between 70-90oC .If temperature attains more than 90oC then switch off the MCB mounted on boiler panel for the power supply of Heaters.
5.4.5 Check water level Indicator (Gauge Glass) on water level indicator mounted on the boiler. It shall be always in between high and low levels marked on the level indicator sight glass.
5.4.6 Turn the selector switch and select Feed water pump no. 1 or 2 .Then put selector Switch marked as “F.P Control switch” in Auto mode.
5.4.7 Start main furnace oil pump.
5.4.8 Check that temperature setting of furnace oil is in between 100ºC to 120ºC, which can be seen by thermostat on temp controller.
5.4.9 Ensure the temperature setting of furnace oil is 100ºC cut-in and 125ºC cut – off mounted on boiler panel .Which can be seen by temperature indicator and controller.
5.4.10 Turn the selector switch to “ON” position mounted on boiler panel marked as “Heater ON/OFF”.
5.4.11 Turn the purging level to ‘P’ position i.e. to purging for 5 minutes.
5.4.12 Turn the burner ON/OFF selector switch mounted on boiler panel to ON position.
5.4.13 Turn the selector level to ‘A’ position i.e. in Auto Mode. Heater will cut off when FO temperature reaches below or above the set temperature. Boiler will restart after few seconds and boiler goes in firing mode.
5.4.14 Ensure that flame is established, which can be seen by view panel.
5.4.15 If not then boiler will go into the lock-out mode. Reset boiler by pressing push button.
5.4.16 Check that the steam pressure in the boiler is minimum 1.0 Kg/cm2. If it is less then open air relief valve.
5.4.17 Turn the firing rate control switch to low firing for 10 Min.
5.4.18 After 10 min, turn firing rate control switch to medium firing for 10min.
5.4.19 Close Air relief valve mounted above the boiler after steam pressure attends1.0Kg/cm².
5.4.20 Open steam stop valve when pressure gauge shows 5 Kg/cm2.
5.4.21 Turn firing rate control switch to “Auto mode” after one normal cut off by steam pressure switch.
5.4.22 Open blow down valve for 30-40 seconds after every 8 Hours of operation.
5.4.23 Drain water level indicator gauge glass after every operation of 8 Hours.
5.4.24 Drain mobbery water for 15 to 20 second by drain valve after every operation of 8 hours.
5.5 Stopping Procedure
5.5.1 Turn off the burner switch.
5.5.2 Switch off furnace oil circulation pump.
5.5.3 Switch off furnace oil preheated.
5.5.4 Maintain 80% water level in gauge glass which can be seen in water level Indicator.
5.5.5 Operate blow down valve for 30-40 seconds approx.
5.5.6 Drain mobbery water.
5.5.7 Close main steam stop valve. Water level should be 60-80% shown in water level Indicator.
5.5.8 Switch off main power supply which is mounted on boiler panel.
5.6 Operation Using Diesel
5.6.1 Check the level of boiler feed water tank and HSD oil tank. Level shall be maintained above half level of the tank capacity in both feed water tank and HSD oil in Day Tank
5.6.2 Open the outlet valve of boiler feed water tank and HSD oil Tank.
5.6.3 Ensure HSD day tank temperature should be between 10ºC – 15ºC.
5.6.4 Start main HSD oil pump.
5.6.5 Turn the selector switch on for firing.
5.6.6 At the time of this period oil heater should be switched off.
5.6.7 HSD temp should be maintained between 15 ºC – 25 ºC.
5.7 Stopping Procedure.
5.7.1 Turn off the burner switch.
5.7.2 Switch off HSD circulation pump.
5.7.3 Switch off Pre-heater.
5.7.4 Maintain 80% water level in gauge glass.
5.7.5 Operate blow down valve up to 30 to 40 seconds approx.
5.7.6 Drain mobbrey water.
5.7.7 Close main steam valve.
5.7.8 Switch off main power supply which is mounted on boiler panel.
5.8 Note down the operation parameter as per format no.
6.0 Forms and Records
6.1 Boiler Operation record – Annexure-1
7.1 Master copy – Documentation Cell (Quality Assurance)
7.2 Controlled copies – Engineering Department