Title: Operation of Boiler
- Objective:
To lay down a procedure for the Operation of Boiler.
- Scope:
This procedure is applicable for the Operation of Boiler.
- Responsibility:
3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down for the Operation of Boiler as per this SOP.
3.2 Quality Assurance Department: To review and approve the SOP and Annexure. To ensure compliance of the SOP.
- Accountability:
Head, Engineering Department / Head, Quality Assurance Department.
- Procedure:
- Definitions:
5.1.1 Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.
- Preventive Maintenance: Maintenance activity performed to ensure that the equipment will function smoothly and to avoid breakdowns. These activities are performed as per predefined frequency.
5.2. Operational Procedure:
| Safety Precautions/Instructions: | ||
| 5.2.1 | Wear appropriate Personal Protective Equipment while operation. | |
| 5.2.2 | Ensure all the electrical connections are properly earthed. Ensure that the power plug of the Boiler is fixed in the socket properly. | |
| 5.2.3 | Inspect electrical cables and connectors for any sign of damage. | |
| 5.2.4 | Ensure that the ON/OFF button is working properly. | |
| 5.2.5 | Ensure that Fuel Temperature Controller setting and Steam Temperature Controller is not altered. | |
| 5.2.6 | Ensure that the drain valve of Economizer, Fuel, and Strainer Drain valve and coil blow down valves are closed. | |
| 5.2.7 | During running check the Boiler for any abnormal sound. | |
| 5.2.8 | During running check the water flow and fuel flow. | |
| 5.2.9 | Reddish flame indicates that the air supply is insufficient. | |
| 5.2.10 | During running check the exhaust from the Chimney. It should be almost colourless. If not inform the HOD. | |
| 5.2.11 | Check the Boiler for any leakages of fuel gases. | |
| 5.2.12 | Ensure that boiler feed water is meeting the specification of hardness and pH. | |
| Operation: | ||
| 5.2.13 | Open the water supply line valve by rotating it in anti clockwise direction. | |
| 5.2.14 | Put the electrical Miniature Circuit Breaker “ON” and the knob pointer should be set above 100C of the saturation temperature of steam. | |
| 5.2.15 | Close the main steam by rotating the valve in clockwise direction and open the auxiliary steam by rotating the valve in anti clockwise direction. | |
| 5.2.16 | Open the fuel line by rotating the valve in anti clockwise direction. | |
| 5.2.17 | Switch “ON” the ‘FILL’ switch to fill up the water in the coil. | |
| 5.2.18 | Start the boiler by rotating the knob in clockwise direction located at the panel board. | |
| 5.2.19 | Green Burner lamp will be turned on indicates the fuel spray starts and sparking stops when the flame is established. | |
| 5.2.20 | When the pressure starts increasing and temperature reached about 130ºC, open the main steam valve by rotating it in anti clockwise direction and simultaneously close the auxiliary steam valve by rotating it in clockwise direction. | |
| Shut down of Boiler: | ||
| 5.2.21 | Close the steam valve fully by rotating it in clockwise direction. The pressure switch will be automatically cut-off from the boiler. | |
| 5.2.22 | Open the coil blow down valve fully by rotating it in anti clockwise direction. | |
| 5.2.23 | Close the blow down valve by rotating it in clockwise direction. | |
| 5.2.24 | Open the auxiliary steam valve fully by rotating it in anti clockwise direction. | |
| 5.2.25 | Finally drain the Economizer by rotating it in anti clockwise direction. Keep its drain valve open till clear water starts coming out. | |
| 5.2.26 | Close the valve of Economizer by rotating it in clockwise direction after the water drains come out completely then press the ‘FILL’ switch off. | |
| 5.2.27 | Close the auxiliary valve and put off the electric main switch. | |
| 5.2.28 | Clean any drip oil, water etc. from the unit. | |
| 5.2.29 | Close the outlet valves of Soft water, Service tank and Fuel oil service tank. | |
| Preventive Maintenance | ||
| 5.2.30 | Perform the Preventive Maintenance as per Annexure. | |
| 5.2.31 | Affix the “Preventive Maintenance Status Label” on the Boiler as per SOP. | |
| 5.2.32 | If Preventive Maintenance activity is outsourced, the observations are to be transcribed in the Annexure and external party certificate to be attached. | |
| Action Plan During Breakdown of Boiler | ||
| 5.2.33 | If any breakdown occurs, inform Head of the Department and Quality Assurance Department. Put the tag “Equipment Under Maintenance, Do Not Start” as per SOP and inform to Service Engineer for rectification. | |
- Abbreviation:
| Abbreviation | Expansion |
| UTL | Utility |
| HOD | Head of Department |
| No | Number |
| etc | Etcetera |
| °c | Degree Celsius |
*Note – Ready to use SOP available in “DOWNLOAD” Section.