Department: Maintenance Issue Date: 01.03.06 Subject Boiler.

REVISIONS Revision Description Original Issue

DOC. No. : AV/ME/WI/020 Page No. : Page 1 of 5 Revision No. & Date : (00)01.03.06

Revision Revised No. Pages 00 0

Date of Revision 01.03.06

Prepared By Maintenance Officer

Approved By Management Representative CLASSIFIED: Internal Use Only

Authorized by Factory Manager

Department: Maintenance Issue Date: 01.03.06 Subject Boiler.

DOC. No. : AV/ME/WI/020 Page No. : Page 2 of 5 Revision No. & Date : (00)01.03.06

1.0 PURPOSE: To ensure the smooth operation of boiler. 2.0 RESPONSIBILITY: 1. Boiler operator 2. Maintenance Engineer. 3.0 PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8. Fuel filter and strainer should be cleaned daily. Feed water quality should be checked periodically. Match the frequency of blow down with the feed water quality. Clean the level switch and gauge glass at weekly basis. Confirm the greasing of all related areas. Nozzles of boiler should be cleaned on the daily basis. Drain the water service tank once in a month and get it cleaned to avoid the sediments if any. Final discharge pressure should be maintained at 10kg/cm2.

CONTROL POINT: Function of safety system and tuning of nozzles. CORRECTIVE ACTION PLAN: Safety system is checked time-to-time and tuning of nozzles also 3.1 STEPS BY STEP INSTRUCTION: 1. After all OK start the boiler in low position. 2. Check the blower fan for necessary air supply for the oxygen required to oil burn efficiently. 3. Check oil pump, oil pressures adjust if required. 4. Checks functioning of firing, air and oil nozzle spraying, photo sensing system.
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Department: Maintenance Issue Date: 01.03.06 Subject 5. Boiler.

DOC. No. : AV/ME/WI/020 Page No. : Page 3 of 5 Revision No. & Date : (00)01.03.06

6. 7. 8. 9. 10. 11. 12.

13.

Keep position of switch in high flame for increasing the efficiencies, then three port solenoid valve is energized releasing oil pressure from the ram and from the rear of second cut off valve, and spraying from the second nozzle and is ignited by the existing flame, the burner is then on high flame. Now boiler in full working position. Check the steam increasing pressure in the pressure gauge and wait till that the pressure reached 5kg, then open the steam discharge valve of boiler. Check the safeties of high-low limit series working within limit. Check the working of PRV; maintain the discharge pressure 3.5 to 5kg. Ensure the soft water hardness within 10 PPM. Check functioning of automatic blow down system within the desire TDS limit highest 3000 PPM and PH- 10.5 to 11.5. During the operation drain the mobri water every after two-hour. Check the burner operation on high or low flame in response to the demand of the high/low controls thermostat or pressure switch. It is only necessary for this control energizes the three-way solenoid valve when calling for heat and to de-energize it when satisfied. Check the smoke of boiler discharge chimney; it should be co lour less.

SHUT DOWN PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8. 9. After the production close the FO tank supply valve. Switch OFF the boiler pre-heater and process tank heater. Empty out the FO from connected pipe line (delivery & return FO line). Switch OFF the operated oil pump and blower fan and burner assay. Keep water pump continuous in auto start as for when the boilers water and chamber cools completely. Close the water inlet valve. Keep empty to the more water. Regenerate to the pre-softener of soft water tank. Check the PH & TDS of boiler water, if both are higher then drain it.

Prepared By Maintenance Officer

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Authorized by Factory Manager

Department: Maintenance Issue Date: 01.03.06 Subject 10. Boiler.

DOC. No. : AV/ME/WI/020 Page No. : Page 4 of 5 Revision No. & Date : (00)01.03.06

Dismantle to the burner inner assembly and clean the diffuser plate, nozzle, inner assembly, plunger needle, blower fan and dumper and remove unwanted material. CRITICAL CONTROL POINTS: 1. 2. All thermostats, pressure switches and safety system should be in the working condition. Ensure the high limit instrument which acts as a safe guard is set sufficiently far above the ON/OFF instrument to eliminate tripping on over swing of pressure or temperature, yet will shut. The burner should be down before overheating. Ensure the necessary air to give the required oxygen to make oil burn efficiently, cleanly and continuously furnished by the fan; the fan is directly attached to the shaft of the fan motor. The air for combustion should be approx 40CFM/IMP. Gal of oil; which equals 14.95 M3/hr per liter of oil. Ensure the ignition transformer out put is 15000 Voltage to spark electrodes for firing. Ensure the oil temperature and oil pressure is correct for operation of the boiler 1100C to 135OC, pressure- 300PSI. Ensure the functioning of mobri float and switches, limit of water, are as per standard water gauge glass level. Ensure the TDS of boiler should not exceed than 3000PPM and PH between 10.5 to 11.5. Steam pressure limit safety should work properly above 10 KG. Boiler feed water hardness should be within 10 PPM. Clean the furnace tube with the wire brush monthly basis and remove unwanted material. Check the every months boiler tube, chamber and joints with the hydraulic pressure.

3.

4. 5. 6. 7. 8. 9. 10. 11.

CORRECTIVE ACTION PLAN: 1. Drain the water service tank once in a month and get it cleaned to avoid the sediments if any.
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Department: Maintenance Issue Date: 01.03.06 Subject Boiler.

DOC. No. : AV/ME/WI/020 Page No. : Page 5 of 5 Revision No. & Date : (00)01.03.06

2. Final discharge pressure is maintained at 5 to 10 kg/cm2 in case increase of pressure safety cut off should work automatically, incase of non functioning of auto safety stop the machine immediately till the fault rectified. 3. Mobri and float switches in perfectly working condition as for low limit and high limit of water level. 4. Clean the diffuser plates every day after production. 5. Check functioning of the oil heater thermostat working at desired temperature. 6. Check the air blower functioning in low and high during operation. 7. Check the feed water Non return valve if leakage or back/return pressure persists rectify the same immediately. 8. Dismantle the bottom door of chimney and remove deposited carbon on weekly basis. 9. Drain the water service tank once in a month and get it cleaned to avoid the sediments if any. Reference: Boiler Manual

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Authorized by Factory Manager