Boiler; standard operating procedures

Boiler operations

Four main topics :-

1. Maintenance

2. Operations & boiler water

3. Management of boiler & engine room

4. Common problems & corrective actions

1. Boiler Maintenance

Daily check :- Density meter, smoke lens, feed pumps, engine running log.

Weekly check : - ID Fan & all Fan, multicyclone separator, furnace condition, boiler tube nest.

Monthly check : - Service smoke density meter, clean lense, FD, Secondary & fuel feeder fans, deaerator pumps, chemical dosing pumps.

Quarterly :- Softener on its resin level & condition, calibration of smoke density meter.

2. Boiler operations

Daily check : - water quality, turbidity index & SSolid, water treatment analysis, engineer to decide dosage, hardness, adequate water supply, smoke density chart, boiler log, use of 90% fibre, even spread of fuel, deashing time below 10 minutes per boiler, reserve dry fibre & shell.

Consistent fuel supply, boiler alarm systems, boiler recorder chart, meal break time / changeover of shift.

3. Management of boiler house

• Annual overhauling & DOSH inspection during low cropping month.
• Preplanned 3 months earlier.
• Operate 3 boiler at all time.
• Turbine operations according to load.
• Close liaison with nearby community.

4. Common problems

• Blacksmoke caused by incomplete combustion.
• Boiler overloading.
• Particulate fall out.
• Inconsistent fuel supply.
• Heavy blowdown of water.
• Too frequent deashing.
• Longer deasing time.
• Complaint by nearby resident.
• Water catchment during dry season.
• no certified steam engineer & boilerman/engine driver.