To describe a standard operating procedure for breakdown rectification of boiler.
1.0 PURPOSE:
To describe a standard operating procedure for breakdown rectification of boiler.
2.0 SCOPE:
The standard operating procedure describes in detail the method of breakdown rectification of boiler. It includes rectification of burnt motor of ID & FD fans, replacement of pulleys of motor and ID fan shaft, replacement of ID fan bearings, replacement of V-belts of ID fan, rectification of steam injector, replacement of couplings of feed water pump and motor, replacement of bearings of feed water pump motor, ID & FD fan motor, rectification of short supply and no water supply to boiler.
3.0 RESPONSIBILITY:
The responsibility of carrying out breakdown rectification of boiler lies with the staff of rank not lower than the boiler operator of maintenance department.
The responsibility of preparing, reviewing and approving the standard operating procedure lies with the Manager - Maintenance, Head of Production and Head of QAD respectively.
4.0 METHOD:
4.1 Rectification of burnt motor of ID & FD fans.
4.1.1 Isolate the equipment electrically and remove the guard.
4.1.2 Remove the motor bolts and remove V-belts.
4.1.3 Remove the motor from the equipment and send it for repairs.
4.1.4 After receiving the motor, check and fix it to the equipment and fix the V-belts.
4.1.5 Fix the guard.
4.1.6 Restore the power supply to the equipment.
4.2. Replacement of pulleys of motor and ID fan shaft.
4.2.1 Isolate the equipment electrically, remove guard and V-belts.
4.2.2 Remove the motor/ID fan shaft pulley using puller.
4.2.3 Fix the new pulley to motor/ID fan shaft and V-belts.
4.2.4 Fix the guard.
4.2.5 Restore the power supply to the equipment.
4.3 Replacement of ID fan bearings:
4.3.1 Isolate the equipment electrically and remove guard.
4.3.2 Loosen the motor base bolts and remove V-belts.
4.3.3 Remove V-pulley of fan shaft using puller.
4.3.4 Remove two plumber blocks from the shaft and take out old bearings.
4.3.5 Insert new bearings in the plumber blocks and lubricate them.
4.3.6 Fix them to the shaft in their respective places.
4.3.7 Fix the V-pulley.
4.3.8 Fix the V-belts.
4.3.9 Tighten the motor base bolts.
4.3.10 Fix the guard.
4.3.11 Restore the power supply to the equipment.
4.4 Replacement of V-belts of ID fan.
4.4.1 Carryout the steps 4.3.1, 4.3.2, 4.3.8 to 4.3.11.
4.5 Rectification of steam injector.
4.5.1 Remove the injector.
4.5.2 Dismantle the injector.
4.5.3 Lap the all mating surfaces using lapping compound.
4.5.4 Assemble the injector.
4.5.5 Fix it to the boiler.
4.5.6 Check the injector water line. If there is any scale in the line remove it by hammering.
4.6 Replacement of couplings of feed water pump and motor.
4.6.1 Start the injector and ensure that the injector is working satisfactorly.
4.6.2 Carryout replacement of couplings as per SOP REPLACEMENT OF DAMAGED COUPLINGS/PULLEYS OF REACTORS, PUMPS, MOTORS AND GEAR BOXES.
4.7 Replacement of damaged bearings of motor for feed water pump, ID & FD fans.
4.7.1 Carryout replacment of bearings as per SOP REPLACEMENT OF BEARINGS OF PROCESS / UTILITIES / LABORATORY EQUIPMENT.
4.8 Rectification of short supply or no water supply to the boiler.
4.8.1 Isolate the equipment electrically.
4.8.2 Replace the pump by standby pump.
4.8.3 Restore the power supply to the equipment.
4.8.4 Send the pump (multi stage) for rectification as per SOP SENDING OUT EQUIPMENT FOR RECTIFICATION TO THE OUTSIDE AGENCY.
4.9.0 Leakage of water from the tubes.
4.9.1 If any leakage is observed from the tubes, replace the tubes through an authorised agency approved by inspectorate of Boilers.
4.10.0 Damaged furnace lining.
4.10.1 Furnace lining repair work can be done by an external agency.
5.0 RECORDING
The responsbility of recording the breakdown in the history card lies with the staff of rank not lower than the maintenance engineer.
Rectification of boiler, engineering, bearings of feed water pump motor
