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Standard Operating Procedure For Boiler

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Temitope Ifelaja
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171 views5 pages

Standard Operating Procedure For Boiler

Uploaded by

Temitope Ifelaja
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Standard Operating Procedure (SOP) for the P.M.

D Industrial Boiler

Purpose
This Standard Operating Procedure (SOP) outlines the steps for safe operation, maintenance, and
troubleshooting of the HYGNIS industrial 4-turns boiler. To ensures the boiler operates
efficiently, safely, and within regulatory requirements.

1. Scope

This SOP applies to the operation, inspection, and maintenance of the P.M.D HYGNIS industrial
4-turns boiler system used during the P.M.D operations for steam generation. This document
covers routine operations, start-up, shutdown, emergency procedures, and preventive
maintenance.

2. Definitions

 Boiler: A vessel that heats water to produce steam or hot water for industrial use.
 4-Turns 3 stage Boiler: A boiler design with four combustion gas passes before exiting
through the flue.
 Burner: The component that supplies heat to the boiler by burning fuel.
 Steam Drum: A storage vessel for steam and water within the boiler.
 Feedwater: Water supplied to the boiler to be heated and converted into steam.

3. Responsibilities

 Operators: Ensure the safe and efficient operation of the boiler, follow all startup,
operational, and shutdown procedures.
 Maintenance Personnel: Perform routine and preventive maintenance as scheduled.
 Safety Officers: Oversee adherence to safety protocols and ensure compliance with
safety standards and local regulations.
 Supervisors: Monitor overall boiler operation, performance, and training of operators.
4. Personal Protective Equipment (PPE)

 Hard hat
 Safety glasses
 Heat-resistant gloves
 Ear protection
 Flame-resistant clothing
 Steel-toe boots

5. Pre-Operation Inspection

Before starting the boiler, the following checks should be performed:

1. Fuel Supply: Ensure that the fuel supply (e.g., natural gas, oil) is adequate and the fuel
valves are in the correct position.
2. Water Levels: Confirm that the feedwater tank is filled and that water levels are within
operational limits.
3. Valves and Gauges:
o Inspect all pressure gauges and safety valves.
o Ensure blowdown valves are closed.
o Verify that water level gauges are operational.
4. Burner Check: Inspect the burner for cleanliness, proper alignment, and readiness for
ignition.
5. Electrical Connections: Confirm that electrical systems, control panels, and power
supplies are functioning properly.

6. Start-Up Procedure

6.1 Initial Start-Up

1. Ensure Safe Conditions: Confirm that the area around the boiler is free of hazards, and
all personnel are clear of the system.
2. Open Feedwater Valve: Ensure that the feedwater valve is fully open.
3. Turn on Control System: Activate the boiler’s control panel.
4. Ignition Sequence:
o Set the boiler to low fire mode.
o Start the burner by engaging the ignition system.
o Monitor the flame to ensure it stabilizes.
5. Monitor Water Levels: Ensure that the water level remains steady and within safe
limits.
6. Gradually Increase Load: Slowly increase the firing rate to bring the boiler up to the
required pressure and temperature.
7. Monitor Operating Parameters: Check all relevant indicators such as:
o Pressure gauge
o Temperature gauge
o Fuel consumption
o Flue gas analysis (if applicable)

6.2 Continuous Operation

1. Monitor Pressure: Ensure the boiler maintains steady pressure according to the
operational setpoints.
2. Water Levels: Regularly check the water level and ensure the feedwater pump is
operating correctly.
3. Check Combustion: Continuously monitor the burner flame for consistency. If the flame
is irregular, shut down the boiler immediately and investigate.
4. Inspect Valves: Ensure all safety valves, pressure relief valves, and blowdown valves are
operating correctly.
5. Record Keeping: Log hourly operational parameters such as pressure, temperature, fuel
consumption, and water levels in the control room logbook.

7. Shutdown Procedure

7.1 Normal Shutdown

1. Reduce Load: Gradually lower the firing rate until the boiler is in low fire mode.
2. Turn Off Burner: Deactivate the burner by shutting down the ignition system.
3. Close Fuel Valves: Ensure the fuel supply valves are closed securely.
4. Allow Boiler to Cool: Let the boiler cool down gradually to prevent thermal stress.
5. Drain the Boiler (if required): If the boiler needs to be taken offline for maintenance,
carefully drain the water using the designated blowdown valve.
6. Turn Off Control System: Shut down the control panel and electrical systems.

7.2 Emergency Shutdown

1. Press Emergency Stop: In case of an emergency (e.g., unsafe pressure, boiler failure),
press the emergency stop button on the control panel.
2. Shut Off Fuel Supply: Immediately close the fuel supply valves to stop fuel from
entering the system.
3. Vent Pressure: If necessary, vent excess steam pressure through the appropriate valves.
4. Evacuate Area: Ensure all personnel evacuate the area until the situation is safe.

8. Maintenance Procedures
8.1 Daily Maintenance

 Check water levels and ensure the feedwater pump operates correctly.
 Inspect for any fuel or water leaks.
 Verify that the pressure and temperature gauges are within normal operating ranges.
 Clean air filters and check for proper burner operation.
 Blowdown the boiler every 4 hours to remove sediments from the water drum.

8.2 Weekly Maintenance

 Blowdown the boiler to remove sediments from the water drum.


 Test all safety valves and pressure relief valves.
 Inspect the burner for any signs of wear, corrosion, or buildup.
 Inspect and clean the side glass.

8.3 Monthly Maintenance

 Clean the boiler tubes and heat exchange surfaces.


 Conduct a combustion analysis to ensure the burner operates at optimal efficiency.
 Inspect and clean the flue gas path to prevent blockages.

8.4 Annual Maintenance

 Perform a thorough internal and external inspection of the boiler.


 Pressure tests the boiler and all associated piping.
 Replace any worn-out gaskets, seals, or components.
 Inspect all electrical connections, sensors, and control systems.

9. Troubleshooting

Issue Possible Cause Solution


Faulty feedwater pump or low water in Check feedwater system and refill
Low Water Level
the tank tank
Burner Fails to
Fuel supply issue or ignitor malfunction Check fuel valves and ignitor
Ignite
Safety valve malfunction or excessive
High Pressure Check and reset safety valves
steam load
Blocked burner nozzle or insufficient Clean burner and ensure proper
Irregular Flame
airflow airflow
Low water level or faulty temperature Check water level and temperature
Overheating
control sensor
10. Safety Precautions

1. Regular Inspection: Perform routine safety inspections to identify and address any
potential hazards.
2. Emergency Procedures: Ensure that all personnel are familiar with emergency
shutdown procedures.
3. Training: All operators and maintenance personnel should be fully trained and certified
for boiler operation.
4. Permit-to-Work System: Enforce a permit-to-work system for all major repairs or
maintenance.
5. Combustible Materials: Keep the area around the boiler free from any combustible
materials.

11. Documentation

Maintain detailed records of the following:

 Boiler start-up and shutdown logs


 Maintenance logs and reports
 Inspection reports and certification records
 Operational parameters (e.g., pressure, temperature)
 Emergency shutdown incidents and corrective actions

12. References

 Manufacturer’s Manual for the 4-Turns Boiler


 Local Regulatory Guidelines for Boiler Operation
 Industry Best Practices for Boiler Safety

Approved By: ____________________

Date: 10/11/2024

Next Review: ____________________

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