Preventive Mantenance of Boiler feed water pump

SMP OF BFP

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Preventive Mantenance of Boiler feed water pump

SUMMARY OF THE OBJECTIVE

This document explains the safe, sequential and logical Step of Preventive
Maintenance of Boiler feed water pump and its auxiliaries.

1. SCOPE
This SOP is applicable for Recommendation on any improvement in the maintenance of
the Facility, together with reasons therefore

2. ABREVIATIONS/NOTATIONS

2.1. SMP: Standard Maintenance Procedure

2.2. SIC: Shift In charge

2.3. E&I E: Electrical & Instrument Engineer

2.4. SM: Station Manager

2.5. FE: Field Engineer

2.6. ME: Mechanical Engineer

2.7. HOM: Head of Maintenance

Caution

Corrective Action

Tripping / Unsafe Condition

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Preventive Mantenance of Boiler feed water pump

3. RESPONSIBILITY:
Station Manager, Head of Maintenance, Shift In Charge, Maintenance Engineer, Field Engineer

4. OHS RISK:

HAZARD IDENTIFICATION, RISK ASSESSMENT AND ESTABLISHMENT OF

CONTROLS

Likelihoo
Severity              
d
         
Example
Rattin
  Personn     Rating        
g
el Injury        

Maintenanc
Boiler e Boiler Fall or Slip or House
NR Injury 1 2 2 Low 1 1 1 Low
Pumps Feed Water Trip keeping
Pump

Maintenanc
Training,
Boiler e Boiler Limbs caught in
NR Injury 1 1 1 Low Machine 1 1 1 Low
Pumps Feed Water nip
Guards
Pump

Hand
Maintenanc
gloves,
Boiler e Boiler Contact With
NR Injury 1 2 2 Low safety 1 1 1 Low
Pumps Feed Water Sharp Edges
shoes,
Pump
helmet

Maintenanc Hand
Boiler e Boiler Failure of gloves,
NR Burn Injury 1 2 2 Low 1 1 1 Low
Pumps Feed Water Gaskets/seals goggles
Pump boiler suit,

Maintenanc
Improper
Boiler e Boiler
NR Handling of Injury 1 1 1 Low Training 1 1 1 Low
Pumps Feed Water
Tools
Pump

Maintenanc
Boiler e Boiler Exposure to
NR Discomfort 1 2 2 Low Ear Plug 1 1 1 Low
Pumps Feed Water Noise
Pump

Maintenanc
Burn due to Leather Lo
Boiler e Boiler
NR contact with Hot Burn Injury 1 2 2 Low Hand 1 1 1
Pumps Feed Water w
surfaces Gloves
Pump

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Preventive Mantenance of Boiler feed water pump

Maintenanc Hand
Boiler e Boiler
NR
Contact with
Discomfort 1 2 2 Low
gloves
1 1 1
Lo
Pumps Feed Water Oil/ Grease Safety w
Pump Shoes.

Provision of
rest at
Maintenanc Intervals,
Working in hot Lo
Boiler e Boiler drinking
NR surroundings/He Discomfort 1 2 2 Low 1 1 1
Pumps Feed Water water, hand w
at radiation
Pump gloves,
safety
shoes.

Maintenanc
e High & Removal of
Boiler Low
NR
Fall or Slip or
Injury 1 2 2 Low
spilled oil,
1 1 1
Lo
Pumps Pressure Trip water w
Dosing logging
Pump

Maintenanc
Hand
e High &
gloves, Lo
Boiler Low Contact With
NR Injury 1 2 2 Low safety 1 1 1
Pumps Pressure Sharp Edges w
shoes,
Dosing
helmet
Pump

Maintenanc
e High & Hand
Boiler Low
NR
Failure of Irritation/Allerg
1 2 2 Low
gloves,
1 1 1
Lo
Pumps Pressure Gaskets/seals y/ Injury goggles w
Dosing boiler suit,
Pump

Maintenanc
e High &
Improper Lo
Boiler Low
NR Handling of Injury 1 1 1 Low Training 1 1 1
Pumps Pressure w
Tools
Dosing
Pump

Maintenanc
e High & Hand
Boiler Low
NR
Contact with
Discomfort 1 2 2 Low
gloves
1 1 1
Lo
Pumps Pressure Oil/ Grease Safety w
Dosing Shoes.
Pump

Maintenanc
e High & Hand
Boiler Low
NR
Contact With Allergy/Irritatio
1 2 2 Low
gloves
1 1 1
Lo
Pumps Pressure Chemicals n Safety w
Dosing Shoes.
Pump

5. SPECIAL SAFTEY PRECAUTIONS:

As appended above

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Preventive Mantenance of Boiler feed water pump

SAFTEY PRECAUTIONS:

a) Ensure the workmen worn required PPE’s.

b) Visitor should not move near the work area.
c) Keep the area clean and free from obstruction.
d) Use proper size gloves.
e) Don't touch any equipment other than the equipment taken for
maintenance.
f) Don’t enter work area till the machine stops completely.
g) Ensure the Emergency Push button for the equipment is pressed.
h) Follow the Maintenance Procedure as per OEM.

SPECIAL SAFTEY PPE’s:

1. Heat resistant hand Gloves,
2. Boiler suit,
3. Electric Hand Gloves

SAFTEY PPE’s:

i) Safety helmet
ii) Safety shoes
iii) Safety goggles
iv) Ear Plug

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 Preventive Mantenance of Boiler feed water pump

SPECIAL TOOLS/ EQUIPMENTS:

MECHANICAL EQUIPMENT & INSTRUMENTS

1 6-7mm to 30-32mm Open & Ring spanner
2 36 forged spanner
3 Screw driver,6’’,12’
4 Scre spanner 6’’&12’
5 Led (soldering) wire 0.50mm,1mm
6 Belt slings, rope slings
7 Allen key set box
8 Steel rule 1mtr, 1feet
9 D-shackle
10 Eye bolt m16, m20, m24, m10
box-spanner set with bits 46,41,36,3 2,30,29,28,27,26, 24,22,20. 6,19,17,15,14,
11 13,12,11,10,9,8
12 Teflon hammer, ball pin hammer, 2lb &4lb hammer
13 Number punch, letter punch, center punch
14 Measurement tape 5 mtrs.
15 Inside & outside micro meter, mirror,
16 Dial gauge, magnetic base,
17 Filler Gauge 6”&12”
18 Circlip plier (internal & external)
19 Chain block 5 ton capacity
20 Hammer, chisel, oil stone, scotch pad, blue pest, Vernier caliper,

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Preventive Mantenance of Boiler feed water pump

7. WORK INSTRUCTION

Work Instruction will depend on the type of Preventive Maintenance.

Preventive Maintenance will be carried out in 4 Category
1. Inspection ( Every 3 Months)
2. Minor Repair (Every 6 months)
3. Major Repair (Every 1 Year)
4. Overhauling ( As per OEM recommendation or 5 years of Operation)

Boiler Feed Pump and Lube Oil Pumps Inspection every 3 months
    Responsibility
Sr. No. Activity ME SIC FE E&I
Clean all the parts and connections of the
1 pump & motor  √   √
2 Check pump & motor base bolt  √
Check the condition of coupling and coupling
3 bolts √
4 Check the tightness of the flange  √   √
5 Check condition of lube oil √   √
6 Oil gland leakage checking √
7 Check the lube oil filter clogging. √ √
Clean the suction strainer and replace the
8 gaskets if required √
9 Inspection and servicing of HT breaker √
Minor Repairs every Six Months
    Responsibility
Sr.
No. Activity ME SIC FE E&I
Clean all the parts and connections of the
1 pump & motor  √   √
2 Check pump & motor base bolt  √
Check the condition of coupling and coupling
3 bolts . √
Check the tightness of the flange, check the
4 condition of gasket and replace if required  √   √
5 Check condition of lube oil √   √
6 Oil gland leakage checking √
Clean the suction strainer and replace the
7 gaskets if required √

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Preventive Mantenance of Boiler feed water pump

8 Check the filter clogging. √ √

Check all flanges, union connections and
9 gaskets, if required replace the same √
10 Inspect Bearing for Pump √
11 Inspect Bearing for Motor √
12 Check Alignment √
13 Tightening of all Motor terminals √
14 Inspection of Motor Space heater √
15 Inspection of Power Contactor √
16 Inspection Of VFD √
17 Inspection of Earthing strip √
Major Repairing every 1 year
Responsibility
Sr.NO Activity ME SIC FE E&I
Clean all the parts and connections of the
1 pump & motor  √   √
2 Check pump & motor base bolt  √
Check the condition of coupling and coupling
3 bolts √
Check the tightness of the flange, check the
4 condition of gasket and replace if required  √   √
5 Check condition of lube oil √   √
6 Oil gland leakage checking √
7 Check the filter for clogging or any damage, if √
required replace.
Check all flanges, union connections and
8 gaskets, if required replace the same √
Clean the suction strainer and replace the
9 gaskets if required √
10 Inspect Bearing for Pump √
11 Inspect Bearing for Motor √ √
12 Check Alignment √
13 Check shaft Sleeve √
14 Check Casing Wearing ring √
15 Replace Casing gaskets √
16 Check Balancing assemblies √
Check Bearing for Pump, Change the Bearing if
17 the Clearance is more than the standard. √
Check Bearing for motor, Change the Bearing if
18 the Clearance is more than the standard. √

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Preventive Mantenance of Boiler feed water pump

Check & replace the Mechanical Seal if

19 required. v
Servicing and calibration of all Field
Instruments like PG,TG, Water flow Meter, Dp
20 gauge   √
Servicing and Calibration of all transmitters like
21 Differential, Temperature, Pressure and Flow. √
Servicing of All Motorised Valves and its
22 calibration. √
23 Tightening of all Motor terminals √
24 Inspection of Motor Space heater √
25 Inspection of motor cooling fan   √
26 Inspection of Bus Bar √
27 Inspection of Power Contactor √
28 Inspection Of VFD √
29 Inspection of Earthing strip √
30 Inspection of Over Load relay √
31 Inspection and Servicing HT breaker √

Over Hauling For Pumps

Responsibility
Sr.No. Activity ME SIC FE E&I
Clean all the parts and connections of the
1 pump & motor  √   √
2 Check pump & motor base bolt  √
Check the condition of coupling and coupling
3 bolts, if required replace √
Check the tightness of the flange, check the
4 condition of gasket and replace if required  √   √
5 Check condition of lube oil √   √
6 Oil gland leakage checking √
Clean the suction strainer and replace the
7 gaskets if required √
8 Check the filter clogging. √ √
Check all flanges, union connections and
9 gaskets, if required replace the same √
10 Inspect Bearing for Pump √
11 Inspect Bearing for Motor √
12 Check Alignment √
13 Check shaft Sleeve √

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Preventive Mantenance of Boiler feed water pump

14 Check Casing Wearing ring √

15 Replace Casing gaskets √
16 Check Balancing assemblies √
Check Bearing for Pump, Change the Bearing
17 if the Clearance is more than the standard. √
Check Bearing for motor Change the Bearing
18 if the Clearance is more than the standard. √
25 Replace the Shaft if required √
26 Replace Impeller if required √
27 Rectify Casing anomalies √
28 Replace Coupling Bolt √
29 Do Alignment √
30 Tightening of all Motor terminals √
31 Inspection of Motor Space heater √
32 Inspection of motor cooling fan   √
33 Inspection of Bus Bar √
34 Inspection of Power Contactor √
35 Inspection Of VFD √
36 Inspection of Earthing strip √
37 Inspection of Over Load relay √
38 Inspection and Servicing HT breaker √

MOV ACTIVITY
    Responsibility
Sr.No. Activity ME SIC FE E&I
1 MOV spindle checking √
2 MOV valve cone checking √
3 MOV manual handle condition checking √ √
4 MOV threaded bush checking      
5 MOV manually operation checking √
6 MOV gear checking √
7 MOV graphite gland condition checking √
8 MOV actuator motor operation checking √ √
9 MOV actuator Torque checking √ √
   

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 Preventive Mantenance of Boiler feed water pump

8.0 REFERENCE:
Sr.No. DOCUMENT NAME DOCUMENT NO.
1. OEM Manual
2. SOP
3.
4.
5.
6.
7.

9.0 RECORDS:

Sr.No. TITEL OF RECORD REFERANCE LOCATION OF RETENTION

NO. OF RECORD TIME
RECORD
1 Logbook

2 History Register
3 Preventative
Maintenance Schedule
4 Monthly Report
5 Annual Report

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