Sample Preventive Maintenance Manual for a Packaged Fire

7/28/2019 Sample Preventive Maintenance Manual for a Packaged Fire

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SAMPLE PREVENTIVE MAINTENANCE MANUAL

PACKAGED FIRE TUBE BOILER


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CONTENTS

Introduction 1

Intention 2

Organisational setup 3

Boiler Fault reporting & Repair progression 4

Preventive Maintenance Schedules

Daily 5Weekly 6

Monthly 7

Every Six Months 8Annual 9

Exhibits

Boiler Log 10

Repair Log 11Boiler Monitoring System Form 12

Record of Revisions 14


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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 ensuremaximum equipment readiness.

The intermediate objectives of the PM is as follows:

a) Documenting information relating to maintenance andmaintenance support actions

b) Improvement of maintainability and reliability of systems andequipment 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.


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INTENTION

It is not intended that this manual serve as operating instructionsmanual for any specific boiler or plant.

Due to the wide variety , types and makes of equipments used theguide should be supplemented with manufacturers recommendations

concerning the maintenance and care of of the system.

Therefore specific operating and maintenance instructions asrecommended by the manufacturer should be supplied to the incharge

to complement the PM manual.


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ORGANISATIONAL SETUP AND

CHAIN OF RESPONSIBILITIES

WORKS MANAGER TECHNICAL

ENGINEERING MANAGER

MAINTENANCE SUPERVISOR

SHIFTOPERATOR

SHIFTOPERATOR

SHIFTOPERATOR

RESPONSIBLE FOR

IMPLEMENTATION

OF PM PROGRAM


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REPAIR PROGRESSION

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

IF PROBLEM

DISCOVERED

OPERATER

PERFORM PM

OPERATER REVIEW

PM OUTLINE

ENTER PROBLEM IN

LOG BOOK

IIS PROBLEMA MINOR

REPAIR JOB

ENTER

STATUS IN

LOG BOOK

NOTIFY MAINTENANCESUPERVISOR

MAINTENANCE

SUPERVISOR REVIEW

OPERATER REPAIRIS

MAINTENANCE

QUALIFIED FOR

THE JOB

ENTER SOLUTION

IN REPAIR LOG

IS PROBLEM ASYSTEM

MODIFICATION

ENGINEERING

REVIEW PE

HIRE CONSULTANT

IF NECESSARY

NOTIFY

INSPECTION

AGENCI IF

REQUIRED

HIRE A QUALIFIED

CONTRACTOR

MAINTENANC

E SUPERVISOR

REVIEW

ISENGINEERING

QUALIFIED TO

DO JOB


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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.


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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



ASME section VI and ASME CSD-1 for its specific written instructions


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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





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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





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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





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BOILER LOGMAINTENANCE TESTING AND INSPECTION LOG

BOILER NO. MONTHPRESSURE RATING YEARCAPACITY FUEL USEDPERSON TO NOTIFY IN AN EMERGENCYEMERGENCY TEL. NO.1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

OBSERVE

WATER LVL.

RECORD

PRESSURE

RECORD FUEL GAS

TEMP.

DAILY CHKS.

WEEKLY CHECKS (ENTER DATE)

WEEK 1 WEEK 2 WEEK 3 WEEK 4TEST LOW WATER

CUT OFF

TEST GAUGE

GLASS

OBSERVE FLAME

CONDITION

WEEKLY CHECKS

MONTHLY CHECKS (ENTER DATE)MANUAL LIFT

SAFETY VALVE

SEMI ANNUAL CHECKS

ENTER DATE

REVIEW LINKAGES FLOOR DRAINS

CONDITION DAMPER CONTROLS FLAME DETECTION

DEVICE

OF STOP VALVES LIMIT CONTROL

OR REFRACTORY OPERATINGCONTROLS

TEST FLUE PASSAGEEACH

ITEM

SEMI

ANNUAL

CHECKS

ANNAUL

CHECKS

GENERAL COMMENTS AND SPECIAL OBSERVATIONS


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MECHANICAL /ELECTRICAL REPAIR LOG

DATE OPERATER/

APPROVED BY

REPAIR

ATTENDED BY

STAFF/

CONTRACTOR

BRIEF DESCRIPTION OF

JOB


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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


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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


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Sample Preventive Maintenance Manual for a Packaged Fire

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