PACKAGED FIRE TUBE BOILER

Transcription

1 SAMPLE PREVENTIVE MAINTENANCE MANUAL PACKAGED FIRE TUBE BOILER 1

2 CONTENTS Introduction 1 Intention 2 Organisational setup 3 Boiler Fault reporting & Repair progression 4 Preventive Maintenance Schedules Daily 5 Weekly 6 Monthly 7 Every Six Months 8 Annual 9 Exhibits Boiler Log 10 Repair Log 11 Boiler Monitoring System Form 12 Record of Revisions 14 2

3 INTRODUCTION Preventive maintenance of boilers is required to maintain then in good working condition and to ensure safety. The primary objective of any P M system is to provide for managing maintenance and maintenance support in a manner which will ensure maximum equipment readiness. The intermediate objectives of the PM is as follows: a) Documenting information relating to maintenance and maintenance support actions b) Improvement of maintainability and reliability of systems and equipment by provision of documented maintenance information for analysis. c) Provide the means to schedule,plan,manage and track maintenance. d) Provide data on which to base improvements in the system. Adequate precautions should be taken while maintenance is being performed to protect personnel performing the job,occupants of the building housing the boiler and occuoants of buildings in viscinity of the buiding and last but not the least the equipment itself. 3

4 INTENTION It is not intended that this manual serve as operating instructions manual for any specific boiler or plant. Due to the wide variety, types and makes of equipments used the guide should be supplemented with manufacturers recommendations concerning the maintenance and care of of the system. Therefore specific operating and maintenance instructions as recommended by the manufacturer should be supplied to the incharge to complement the PM manual. 4

5 ORGANISATIONAL SETUP AND CHAIN OF RESPONSIBILITIES WORKS MANAGER TECHNICAL ENGINEERING MANAGER RESPONSIBLE FOR IMPLEMENTATION OF PM PROGRAM MAINTENANCE SUPERVISOR SHIFT OPERATOR SHIFT OPERATOR SHIFT OPERATOR RESPONSIBLE FOR LOG READINGS AND PM CHECKS 5

6 REPAIR PROGRESSION OPERATER REVIEW PM OUTLINE OPERATER PERFORM PM ENTER PROBLEM IN LOG BOOK YES IIS PROBLEM A MINOR REPAIR JOB IF PROBLEM DISCOVERED YES NOTIFY MAINTENANCE SUPERVISOR NO MAINTENANCE SUPERVISOR REVIEW NO OPERATER REPAIR YES IS MAINTENANCE QUALIFIED FOR THE JOB ENTER STATUS IN LOG BOOK ENTER SOLUTION IN REPAIR LOG NO MAINTENANC E SUPERVISOR REVIEW ENGINEERING REVIEW (PE) YES IS PROBLEM A SYSTEM MODIFICATION NO HIRE A QUALIFIED CONTRACTOR YES NOTIFY INSPECTION AGENCI IF REQUIRED IS ENGINEERING QUALIFIED TO DO JOB NO HIRE CONSULTANT IF NECESSARY 6

7 DAILY CHECK LIST BLOW DOWN AND TEST LOW WATER CUT OFF BLOW DOWN GAUGE GLASSES BLOW DOWN BOILER CHECK BOILER AND SYSTEM FOR LEAKS CHECK BURNER FLAME Note: The above check list should also refer to specific written procedures. In all cases the equipment manufacturers recommendation should be followed. This check off list uses ASME section VI and ASME CSD-1 for its specific written instructions. 7

8 WEEKLY CHECKLIST CHECK FLAME SIGNAL STRENGTH FOR BOTH PILOT AND MAIN FLAME CHECK PILOT AND MAIN FUEL VLAVE SHUTOFF VALVES CLOSING CHECK IGNITOR AND BURNER OPERATION CHECK LEVEL IN CHEMICAL TREATMENT TANK Note: The above check list should also refer to specific written procedures. In all cases the equipment manufacturers recommendation should be followed. This check off list uses ASME section VI and ASME CSD-1 for its specific written instructions 8

9 MONTHLY CHECKLIST CHECK BOILER WATER TREATMENT TEST RESULTS AND ADJUST IF NECESSARY. LUBRICATE MOTORS AND EQUIPMENT BEARINGS CHECK MAIN FUEL SAFETY SHUT OFF VALVE FOR LEAKAGES CHECK LOW FIRE START INTERLOCK CHECK HIGH PRESSURE/TEMPERATURE INTERLOCKS CHECK HIGH AND LOW PRESSURE INTERLOCKS ON GAS TRAIN MANUALLY LIFT SAFETY VALVE BY HAND Note: The above check list should also refer to specific written procedures. In all cases the equipment manufacturers recommendation should be followed. This check off list uses ASME section VI and ASME CSD-1 for its specific written instructions 9

10 SIX MONTHLY CHECKLIST INSPECT BURNER COMPONENTS CHECK FLAME FAILURE SYSTEM COMPONENTS CHECK PIPING AND WIRING OF ALL INTERLOCKS AND SHUT OFF VLAVES RECALIBERATE ALL INSTRUMENTS, INDICATING AND RECORDING GAUGES PERFORM A SLOW DRAIN TEST FOR WATER LOW WATER CUT OFF CHECK COMBUSTION CONTROL SYSTEM CHECK OIL ATOMISER NOZZLES AND STRAINERS TEST BOILER SAFETY VALVE AS PER ASME STANDARDS Note: The above check list should also refer to specific written procedures. In all cases the equipment manufacturers recommendation should be followed. This check off list uses ASME section VI and ASME CSD-1 for its specific written instructions 10

11 ANNUAL CHECKLIST PERFORM THE SIX MONTHLY CHECKS CHECK ALL EQUIPENT COILS AND DIAPRHRAGM PERFORM A PILOT TURN DOWN TEST RECONDITION OR REPLACE LOW WATER CUT OFF ASSEMBLY CHECK GAS DRIP LEG AND GAS STRAINER CLEAN BOILER FIRESIDE DRAIN BOILER OPOEN HAND HOLES AND MANHOLES AND CLEAN WATER SIDE HAVE BOILER INSPECTED BY AN COMPETANT & AUTHORISED BOILER INSPECTION AGENT CLEAN BURNER BLOWER PRIMARY AND SECCONDRY FANS REPLACE ALL GASKETS LEAK TEST ALL FUEL VALVES TEST OPERATION OF ALL CONTROLS AND SAFETY DEVICES ADJUST COMBUSTION PARAMETERS FOR LOW AND HIGH FIRE CONDITIONS RETEST AND RE CERTIFY BOILER MONITORING SYSTEM Note: The above check list should also refer to specific written procedures. In all cases the equipment manufacturers recommendation should be followed. This check off list uses ASME section VI and ASME CSD-1 for its specific written instructions 11

12 BOILER LOG MAINTENANCE TESTING AND INSPECTION LOG BOILER NO. MONTH PRESSURE RATING YEAR CAPACITY FUEL USED PERSON TO NOTIFY IN AN EMERGENCY EMERGENCY TEL. NO OBSERVE WATER LVL. RECORD PRESSURE RECORD FUEL GAS TEMP. DAILY CHKS. TEST LOW WATER CUT OFF TEST GAUGE GLASS OBSERVE FLAME CONDITION WEEKLY CHECKS WEEKLY CHECKS (ENTER DATE) WEEK 1 WEEK 2 WEEK 3 WEEK 4 MONTHLY CHECKS (ENTER DATE) MANUAL LIFT SAFETY VALVE SEMI ANNUAL CHECKS ENTER DATE REVIEW LINKAGES FLOOR DRAINS CONDITION DAMPER CONTROLS FLAME DETECTION DEVICE OF STOP VALVES LIMIT CONTROL OR REFRACTORY OPERATING CONTROLS TEST FLUE PASSAGE EACH ITEM SEMI ANNUAL CHECKS ANNAUL CHECKS GENERAL COMMENTS AND SPECIAL OBSERVATIONS 12

13 MECHANICAL /ELECTRICAL REPAIR LOG DATE OPERATER/ APPROVED BY REPAIR ATTENDED BY STAFF/ CONTRACTOR BRIEF DESCRIPTION OF JOB 13

14 BOILER MONITORING SYSTEM NAMES OF BOILER OPERATORS NAMES OF MAINTENANCE CONTRACTING FIRMS LOCATION OF WIRING DIAGRAM LOCATION OF FAULT FINDING AND ANALYSIS CHART HOW TO HANDLE EMERGENCIES 14

15 RECORD OF REVISIONS REVISION NO. REVISED SECTION NO & DESCRIPTION DATED REVISED A COPY OF THIS DOCUMENT WILL BE WITH THE ENGINEERING MANAGER,MAINTENANCE SUPERVISOR AND THE BOILER RECORD ROOM 15

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