Boiler Drum Standard Operating Procedure

IL&FS Tamilnadu Power Company Ltd.
2X600MW Thermal Power Plant

DEPARTMENT: MECHANICAL MAINTENANCE
DOC.REF..NO:
ILFS/MECH/BLR/SMP/01
WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

REV.NO : 00
DATE: 15.10.2015
PAGE 1 of 10
STANDARD MAINTENANCE PROCEDURE

FOR
BOILER DRUM
Revision status Record:

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Revision No. Date
Page no.
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Details of Changes
PAGE 2 of 10
Reason for changes
AMENDMENT HISTORY
Sl
no.
1
Amendment Description
a. Inclusion of new hazard controls
b. Version change
Current Ver.
No.
00
Current
Rev.No
00
Issue Date
28.09.2015

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Table of contents
1. Purpose
2. Scope
3. Responsibility
4. Procedure
4.10 objectives
4.20 Specifications
4.30 Details of risks and Hazards involved
4.40 Safety precautions required
4.50 Isolation Procedure
4.60 T&P required including special Tools & Spares
5. Maintenance Frequency
6. Work Procedure
7. Checks before release of Permit
8. Quality
9. References
10. Appendix-A Mechanical Record Structure
11. PM Check list
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1.0 PURPOSE:
The purpose for this SMP is to give a safe and trouble free procedure to carry out the maintenance
activities of BOILER DRUM.
2.0 SCOPE:
S.No
1.
2.
UNIT
UNIT-I
UNIT-II
Equipment Name
BOILER DRUM
BOILER DRUM
Equipment Code
(As per Block diagram Coding)
(As per Block diagram Coding)
3.0 RESPONSIBILITY:
1) Designation
Staff Level I (Maintenance Engineer)
2)
Primary
Responsibility
Staff Level-II (Section In-Charge )
Secondary
HOD (Mech. Maintenance )
Overall responsibility
Note: Other department to be intimated: (Main Plant Operation, C&I, Electrical, Fire&
Safety)
4.0 PROCEDURE
4.10 OBJECTIVE:

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The objective of this procedure is to ensure systematic work instructions for maintenance crew to ensure hassle
free maintenance and safe work procedure.
4.20
GENERAL SPECIFICATION OF BOILER DRUMS:-
Length
27998 MM
Internal dia.
1778 MM
Material specification
SA 299
Thickness
Weight
Turbo separators
185 (Max), 155 (Min)

247.67 MT
110 (per separator capacity-17.72TPH) Nos
Screen driers
148 Nos
Riser tubes
80 Nos
Saturated link connections
26 Nos
Down comers
6 Nos
Safety Valves
6 Nos
Feed Links
3 No
Design pressure
Design metal temp
Max operating pressure
210.0 Kg/cm2
369C
197.0 Kg/cm2

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PAGE 6 of 10
4.30 DETAILS OF RISKS & HAZARDS INVOLVED:
Failure of lifting tools & tackles.

Contact with hot surface.
Exposure to process liquid.
Suffocation due to confined area.
4.40 SAFETY PRECAUTIONS REQUIRE:
Keep the fire extinguishers ready within reachable limit for any emergency.
Asbestos hand gloves to be used.
Ensure use of periodically tested proper lifting tools & tackles.
Use of earplug and Boiler suit is mandatory along with other general PPEs.
Ensure good housekeeping of in around the area of maintenance.
Put barricade tapes around the equipment under maintenance.
Proper Illumination and ensure the oxygen level availability at the work place.
Exhaust fan to be in use to avoid suffocation due to confined space.
All PPE to be worn while working inside the drum.
Permit Type: Permit to work, Hot work permit, Height work permit.
Permit Approving Authority: Shift in charge
4.50 ISOLATION PROCEDURE

All drains and vents to be opened.
Isolating valves of re-circulation valve to be kept closed.
Isolate Balancing Leak off line.
4.60 T&P REQUIRED INCLUDING SPECIAL TOOLS & SPARES REQUIRED.

SL. NO.
1
2
3
TYPE OF THE TOOL

Oil Pump
Grease Gun
Screw Driver
SPECIFICATI
ON
QUANTITY
1 No
1 No
1 No

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4
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Oil Can with closed cap
SL. NO.
1
2
PAGE 7 of 10
2 Nos
TYPE OF THE MATERIAL

Soft Cotton Cloth
Rustolene
QUANTITY
1Kg
1 No
5.0 FREQUENCY OF MAINTENANCE

Sl no.
Job title
Preventive Maintenance activities: As per the

check list.ref.no: ILFS/MMD/BLR/PM/01
Frequency of maintenance
Annually/Opportunity
6. WORK PROCEDURE:
A. PM PROCEDURE.
B. CONDITION BASED MAINTENANCE
A) OVERHAULING WORK INSTRUCTIONS

Check the pressure & temp of boiler drum.
Both side manhole doors to be opened.
Installation of cooling fan required on one side of the drum man hole door for the proper and effective
cooling / avoid suffocation.
After the cooling inspection to be done inside, ensure that drum inside temperature should be within 35C
Proper checking of the turbo separator, perforated plate, wedge pin, chemical dosing line, CBD line, and
inside tray condition.
After the inspection if both perforated plate & turbo separators are out of position, then put the perforated
plate in position first & then the separator.
After the maintenance and alignment of perforated plate and turbo separator, then the wedge pin should
be locked.
After maintenance all tools & foreign materials are to be removed from the drum inside.

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Cleaning of drum inside to be done after the completion of work, avoiding wiping up off magnetite layer.
Groove between the manhole door and drum to be cleaned & new spiral gasket should be installed &
handled carefully.
After final inspection all the man holes are to be closed.
7. QUALITY CHECKS:
All the parameters, activities are maintained within limit as per the OEM standards.
8. CHECKS BEFORE RELEASE OF PERMIT:
All Tools & materials and manpower are removed.
Clean the maintenance area properly.
Ensure safety protection cover / guards are fitted in its position.
9.0 REFERENCE
OEM Manual.
10. APPENDIX- A Mechanical Record Structure
Daily Report./ Condition monitoring ( Field staff observation Note Book)
PM Checklist. (Ref No: ILFS/MMD/BLR/BOILER DRUM/PM/01)

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PM CHECHKLIST :( Ref No ILFS/MMD/BLR/BOILER DRUM/PM//01)

Name of the Equipment: BOILER DRUM - 01
Work Permit No:
Date:
PAGE 9 of 10

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PAGE 10 of 10

Boiler Drum Standard Operating Procedure

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IL&FS Tamilnadu Power Company Ltd.

2X600MW Thermal Power Plant

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

STANDARD MAINTENANCE PROCEDURE

Revision status Record:

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

Reason for changes

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

Staff Level-II (Section In-Charge )

HOD (Mech. Maintenance )

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

GENERAL SPECIFICATION OF BOILER DRUMS:-

185 (Max), 155 (Min)

Saturated link connections

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

4.30 DETAILS OF RISKS & HAZARDS INVOLVED:

Failure of lifting tools & tackles.

4.40 SAFETY PRECAUTIONS REQUIRE:

4.50 ISOLATION PROCEDURE

4.60 T&P REQUIRED INCLUDING SPECIAL TOOLS & SPARES REQUIRED.

TYPE OF THE TOOL

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

Oil Can with closed cap

TYPE OF THE MATERIAL

5.0 FREQUENCY OF MAINTENANCE

Preventive Maintenance activities: As per the

A) OVERHAULING WORK INSTRUCTIONS

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

PM CHECHKLIST :( Ref No ILFS/MMD/BLR/BOILER DRUM/PM//01)

IL&FS Tamilnadu Power Company Ltd.

WORK INSTRUCTION TITLE: MAINTENANCE OF BOILER DRUM

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