3. The Need:
1.To ensure 100% safe to operate the boiler.
2.To ensure 100% availability for the Production
Requirement.
3.To ensure the boiler runs at its Best efficiency.
4.To ensure the operation to be cost effective.
4. How do we maintain a boiler?
• Requirements
1.Correct Inputs
a. Quality of Water-Feed water & Boiler Water
b. Quality of Fuel
c. Input Voltage
6. General Maintenance
• A well-planned maintenance program avoids
unnecessary down time or costly repairs.
• It also promotes safety.
• An inspection schedule listing the procedures
should be established.
7. • It is recommended that boiler log or record be
maintained, recording daily, weekly, monthly,
and yearly maintenance activities.
• This provides a valuable guide and aids in
obtaining boiler availability factor to
determine shutdown frequency, economies,
length of service, etc.
8. • Even though the boiler has electrical and
mechanical devices that make it automatic or
semi-automatic in operation, these devices
require systematic and periodic maintenance.
• Any "automatic" features do not relieve the
operator from responsibility, but rather free
him from certain repetitive chores, providing
him with time to devote to upkeep and
maintenance.
9. • Good housekeeping helps to maintain a
professional boiler room appearance.
• Only trained and authorized personnel should
be permitted to operate, adjust, or repair the
boiler and its related equipment.
• The boiler room should be kept free of all
material and equipment not necessary for
operation for the boiler.
10. • Alertness in recognizing unusual noises, improper
gauge readings, leaks, signs of overheating, etc.,
can make the operator aware of developing
malfunction and initiate prompt corrective action
that may prevent excessive repairs or unexpected
down time.
• All piping connections to the system and its
accessories must be maintained leak-proof
because even a minor leak, if neglected, may
soon become serious.
11. • This applies especially to the water gauge
glass, water level control, piping, valve
packing, and manhole gaskets.
• If serious leaks occur shut down the boiler
immediately and gradually reduce steam
pressure. Do not attempt to make repairs
while the boiler is under pressure.
12. Daily inspections/maintenance
• Check the boiler water level in the gauge glass
• Check the boiler steam pressure on the gauge.
• Operate the scum and bottom blow down
valve to remove any accumulated floating
particles/solids in the drum.
• The valves on the water column and gauge
glass should be operated to make sure these
connections are clear.
13. • Monitor water chemistry to adjust the
chemical feed treatment and continuous blow
down as required, to remain within water
treatment guidelines established by the
Owner's water treatment consultant.
• Clean the gauge glass externally.
• Clean the fuel filters and strainers.
14. • the burner operation,
• fuel oil pressure,
• atomizing air or steam pressure,
• visual appearance, etc.
Maintain a daily schedule of soot-blowing.
15. • Ensure proper lubrication of all moving parts.
• Clean the flame sensor and viewing glass.
• Check the conditions of door seals.
• Check that there are no variations in the fuel
pressure as compared with that at
commissioning time.
16. Monthly maintenance/inspection
• Check the condition of the refractory for
significant damage or cracking.
• Patch and repair the refractory as required.
• Frequent wash coating of refractory surfaces is
recommended.
• Use high temperature bonding, air-dry type
mortar diluted with water, to the consistency of
light cream, for this purpose.
• This will seal small cracks and prolong the life of
the refractory.
17. • Follow the maker’s recommendations pertaining
to safety valve inspection and testing.
• The frequency of testing, either by the use of the
lifting lever or by raising the steam pressure,
should be based on the recommendation of
maker/ classification society.
• Test the boiler safety valves in accordance with the
manufacturer's instructions to be absolutely sure
that the valves have not corroded. Failure of the
relief valves in an overpressure situation is
DISASTROUS!
18. Monthly Maintenance
• Clean electrical contacts of all relays and tighten
loose connections if any. Rough emery paper
should not be used for cleaning contacts.
• Check water pump gaskets and non-return valves.
• Lubricate the modulation motor linkages.
• Clean the burner nozzle and ignition electrodes.
• Check and clean, if necessary, the furnace.
19. Quarterly Maintenance
• 1.Clean blower fan blades.
• 2.Drain and clean water service / de-aerator
tank and fill it with soft / DM water.
• 3.Clean all the fuel filters / strainers.
• 4.Drain and clean fuel service tank.
• 5.Inspect / overhaul the burner assembly.
20. Half Yearly Maintenance
1.Check all valves for leakage; lap them if found
leaking.
2.Lubricate bearings of water pumps.
3.Check the sealing of Manhole head holes, and
clean out door of smoke box.
4.Clean the inner and outer face of the sight
glass.
21. Yearly Maintenance
• 1.Clean the smoke side with the help of wire brush and
also with water jet.
• 2.Clean the combustion chamber of boiler and, super
heater. However quality of fuel and burner efficiency
will determine the frequency of cleaning this.
• 3.Check the door refractory for any damage. Repair as
necessary.
• 4.Clean the water side of the boiler thoroughly. De-
scaling, if required, should be carried out as given in
the maker’s instruction manual.
• 5. Inspect the condition of all mountings.
