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 5
Weekly 6
Monthly 7
Every Six Months 8
Annual 9

Exhibits
Boiler Log 10
Repair Log 11
Boiler 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 ensure
maximum equipment readiness.

The intermediate objectives of the PM is as follows:

a) Documenting information relating to maintenance and

maintenance support actions

b) Improvement of maintainability and reliability of systems and

equipment 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 instructions

manual for any specific boiler or plant.

Due to the wide variety , types and makes of equipments used the
guide should be supplemented with manufacturers recommendations
concerning the maintenance and care of of the system.

Therefore specific operating and maintenance instructions as

recommended 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

RESPONSIBLE FOR
IMPLEMENTATION
OF PM PROGRAM

MAINTENANCE SUPERVISOR

SHIFT SHIFT SHIFT

OPERATOR OPERATOR OPERATOR

RESPONSIBLE FOR LOG READINGS AND PM CHECKS

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 REPAIR PROGRESSION

OPERATER REVIEW
PM OUTLINE

OPERATER ENTER PROBLEM IN IIS PROBLEM

A MINOR
PERFORM PM LOG BOOK YES REPAIR JOB

NOTIFY MAINTENANCE
SUPERVISOR
IF PROBLEM NO
DISCOVERED

YES MAINTENANCE
SUPERVISOR REVIEW

NO OPERATER REPAIR
IS
MAINTENANCE
QUALIFIED FOR
YES THE JOB

ENTER
STATUS IN
LOG BOOK ENTER SOLUTION
IN REPAIR LOG
NO

IS PROBLEM A
SYSTEM
MODIFICATION
ENGINEERING
YES
REVIEW (PE)
MAINTENANC
E SUPERVISOR
REVIEW
NO
IS
ENGINEERING
YES QUALIFIED TO
DO JOB

HIRE A QUALIFIED
CONTRACTOR

NOTIFY
NO
INSPECTION
HIRE CONSULTANT
AGENCI IF
IF NECESSARY
REQUIRED
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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

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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 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

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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 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

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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 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

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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 BOILER LOG
MAINTENANCE TESTING AND INSPECTION LOG
BOILER NO. MONTH
PRESSURE RATING YEAR
CAPACITY FUEL USED
PERSON TO NOTIFY IN AN EMERGENCY
EMERGENCY 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 2
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OBSERVE
WATER LVL.
RECORD
PRESSURE
RECORD FUEL GAS
TEMP.
DAILY CHKS.

WEEKLY CHECKS (ENTER DATE)

WEEK 1 WEEK 2 WEEK 3 WEEK 4
TEST LOW WATER
CUT OFF
TEST GAUGE
GLASS
OBSERVE FLAME
CONDITION
WEEKLY CHECKS

MONTHLY CHECKS (ENTER DATE)

MANUAL LIFT SEMI ANNUAL CHECKS
SAFETY VALVE ENTER DATE
REVIEW LINKAGES FLOOR DRAINS
CONDITION DAMPER CONTROLS FLAME DETECTION
DEVICE
OF STOP VALVES LIMIT CONTROL
OR REFRACTORY OPERATING
CONTROLS
TEST FLUE PASSAGE
EACH
ITEM

SEMI ANNAUL
ANNUAL CHECKS
CHECKS
GENERAL COMMENTS AND SPECIAL OBSERVATIONS

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 MECHANICAL /ELECTRICAL REPAIR LOG

DATE OPERATER/ REPAIR STAFF/ BRIEF DESCRIPTION OF

APPROVED BY ATTENDED BY CONTRACTOR 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 REVISED SECTION NO & DESCRIPTION DATED

NO. REVISED

A COPY OF THIS DOCUMENT WILL BE WITH THE ENGINEERING

MANAGER,MAINTENANCE SUPERVISOR AND THE BOILER RECORD ROOM

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