SAMPLE PREVENTIVE MAINTENANCE MANUAL PACKAGED FIRE TUBE BOILER

CONTENTS

Introduction Intention Organisational setup Boiler Fault reporting & Repair progression Preventive Maintenance Schedules Daily Weekly Monthly Every Six Months Annual Exhibits Boiler Log Repair Log Boiler Monitoring System Form Record of Revisions

1 2 3 4

5 6 7 8 9

10 11 12 14

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.

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.

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

REPAIR PROGRESSION

OPERATER REVIEW PM OUTLINE

OPERATER PERFORM PM

ENTER PROBLEM IN LOG BOOK

YES

IIS PROBLEM A MINOR REPAIR JOB

NOTIFY MAINTENANCE SUPERVISOR IF PROBLEM DISCOVERED

NO
MAINTENANCE SUPERVISOR REVIEW

YES

NO

OPERATER REPAIR

YES
ENTER STATUS IN LOG BOOK

IS MAINTENANCE QUALIFIED FOR THE JOB

ENTER SOLUTION IN REPAIR LOG

NO
IS PROBLEM A SYSTEM MODIFICATION

MAINTENANC E SUPERVISOR REVIEW

ENGINEERING REVIEW (PE)

YES

NO YES
IS ENGINEERING QUALIFIED TO DO JOB

HIRE A QUALIFIED CONTRACTOR NOTIFY INSPECTION AGENCI IF REQUIRED

NO
HIRE CONSULTANT IF NECESSARY 6

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.

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

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

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

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

BOILER LOG
MAINTENANCE TESTING AND INSPECTION BOILER NO. PRESSURE RATING CAPACITY PERSON TO NOTIFY IN AN EMERGENCY EMERGENCY TEL. NO.
1 OBSERVE WATER LVL. RECORD PRESSURE RECORD FUEL GAS TEMP. DAILY CHKS. 2 3 4 5 6 7 8 9 10 11 12 13 14

LOG MONTH YEAR FUEL USED

15 16 17 18 19 20 21 22 23 24 25 26 27 28 2 9

WEEKLY CHECKS (ENTER DATE) WEEK 1 WEEK 2 WEEK 3

TEST LOW WATER CUT OFF TEST GAUGE GLASS OBSERVE FLAME CONDITION WEEKLY CHECKS

WEEK 4

MONTHLY CHECKS (ENTER DATE)

MANUAL LIFT SAFETY VALVE REVIEW CONDITION OF OR TEST EACH ITEM SEMI ANNUAL CHECKS ENTER DATE LINKAGES DAMPER CONTROLS STOP VALVES REFRACTORY FLUE PASSAGE FLOOR DRAINS FLAME DETECTION DEVICE LIMIT CONTROL OPERATING CONTROLS

SEMI ANNUAL CHECKS

ANNAUL CHECKS

GENERAL COMMENTS AND SPECIAL OBSERVATIONS

12

MECHANICAL /ELECTRICAL REPAIR LOG

DATE OPERATER/ APPROVED BY REPAIR ATTENDED BY STAFF/ CONTRACTOR BRIEF DESCRIPTION OF JOB

13

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

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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