SOP (U): 08.

654

SOP FOR FIRE TUBE BOILER(Gas Fired) 1. FILLING OF THE BOILER

1.1 Be sure water level of Feed tank and Boiler is in workable level. If need, Fill the Feed tank & Boiler only with the treated water; 1.2 Be sure that the blow down valve and main steam valve is closed. If need, close. 1.3 Open air relief valve (Air cock valve). (Need for after longtime and No need when pressure is exist). 1.4 Switch on main circuit breaker and softener pump to fill feed tank with treaded water. Then select the Feed Pump position at Auto (2) to automatically fill boiler. Before switch on the pump be sure that valve is opened. Feed Pump Position: 0 = OFF, 1 = Manual, 2 = Auto.

2. FIRING OF THE BOILER

2.1 Turn ON main gas valve and be sure gas pressure is in workable. 2.2 Be sure power in main panel board by indicator. 2.3 Turn ON the Burner switch at ON position; (a) Blower Motor will ON, (b) Blower will be high then be low accordingly by burner sequence controller.(c)5no Ignition gas indicator will light up. After 45- 50 sec. (d) 6 No Main Gas indicator will light up.

3. SETTING TO WORK.
3.1 Select Burner output control switch on position (2). 1 = Automatic, 2 = Small Load, 3 = Stop, 4 = Full Load 3.2 Close air relief valve when a steam pressure of 0.5 Bar is reached. If you have opened it during filling of the boiler time. 3.3 After reaching the working pressure, open main steam valve on boiler slowly. Then open valves of the steam using section. 3.4 Turn Burner switch to position automatic.

4. BOILER OPERATION
4.1 Keep Feed water temperature at 80C. 4.2 Open blow down valve approx. every 8 hours for a few seconds. 4.3 Test feed water, Softener water and blow down water. Then regenerate softener as per water report. 4.4 Add 200 gm scale and corrosion inhibitor into feed tank every 8 hours. 4.5 Run softener and feed pump alternatively. 4.6 Record steam pressure, gas pressure and water level of feed tank & boiler. 4.7 Record boiler running hours and Flow meter reading.

5 BOILER SHUT-DOWN
5.1 Turn the burner control switch at (2) small load position. 5.2 Switch off the Burner 5.3 Should do following works if the boiler remains out of service for a long time; (a) Release pressure unto 0 by blow down. (b) Close main stop valve of steam and gas and header. Close feed water valve. (d) Switch off main circuit breaker.

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR FIRE TUBE FLUE GAS BOILER 1. FILLING OF THE BOILER
1.1 Be sure water level of Feed tank and Boiler is in workable level. If need, Fill the Feed tank & Boiler only with the treated water; 1.2 Be sure that the blow down valve and main steam valve is closed. If need, close. 1.3 Open air relief valve (Air cock valve). (Need for after longtime and No need when pressure is exist). 1.4 Switch on main circuit breaker and softener pump to fill feed tank with treaded water. Then select the Feed Pump position at Auto (2) to automatically fill boiler. Before switch on the pump be sure that valve is opened. Feed Pump Position: 0 = OFF, 1 = Manual, 2 = Auto.

2. OPENING OF THE DAMPER

2.1 Switch ON damper. 2.2 Set temperature 425C at temperature controller. 2.3 Go to damper to ensure damper on. 2.4 ON another damper on above way.

3. SETTING TO WORK.
3.1 Close air relief valve when a pressure of 0.5 Bar is reached. If you have opened it during filling of the boiler. 3.2 After reaching the working pressure, open main steam valve on boiler slowly. Then open valves of the steam using section. 3.3 Turn Feed pump switch to position automatic.

4. BOILER OPERATION
4.1 Keep Feed water temperature at 80C by continuous running circulation pump. 4.2 Open blow down valve approx. every 8 hours for a few seconds. 4.3 Test feed water, Softener water and blow down water. Then regenerate softener as per water report. 4.4 Add 100 gm scale and corrosion inhibitor into feed tank every 8 hours. 4.5 Run softener and feed pump alternatively. 4.6 Record steam pressure, gas pressure and water level of feed tank & boiler. 4.7 Record boiler running hours and Flow meter reading, pressure, temperature.

5 BOILER SHUT-DOWN
5.1 Switch OFF the damper switches and to ensure is closed. 5.2 Switch off Feed pump. 5.3 Should do following works if the boiler remains out of service for a long time; (a) Release pressure unto 0 by blow down. (b) Close main stop valve of steam and gas and header. Close feed water valve. (d) Switch off main circuit breaker.

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR SCREW COMPRESSOR (AIR COOLED) 1BEFORE STARTING

1.1 Be sure that the oil in the oil tank is workable level. 1.2 Open all doors and visually check that the machine may be operated. 1.3 Open the door of the electrical panel and check whether the three phases are connected securely.

2 STARTING THE COMPRESSOR

2.1 Switch ON the main circuit breaker. 2.2 Press the start button (Green) and check the main motor rotation clockwise when viewed from the front of the compressor. 2.3 Run the compressor for 5 minutes. Stop the compressor and check the oil level. Add or remove oil to bring oil level to half the maximum level in the oil sight glass.

3 SETTING TO THE WORK

3.1 Start the compressor again. 3.2 Set the compressor in the AUTO mode using control panel.

4 MONITORING DURING OPERATION OF THE COMPRESSOR

4.1 Monitor the indicators on the panel regularly. Under the following conditions control panel lights up and the compressor stop automatically. 4.2 High discharge temperature 4.3 Main motor over load 4.4 Fan motor overload. 4.5 Check Auto drain valve or drain manually every 1 hour.

5 STOPPING THE COMPRESSOR

5.1Press the stop button 5.2 Switch off the main circuit breaker.

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR RECIPROCATING COMPRESSOR (WATER COOLED) 1BEFORE STARTING

1.1 Be sure that oil level of the frame (crank case) and cylinder is in the workable level. 1.2 Be sure that water in the cooling tower is ok. 1.3 Turn on the all valves for circulation cooling water. 1.4 Switch ON the circulation pump and CT Fan. Be sure that water circulation by open manual valve on the 2nd stage compressor head. 1.5 Be sure that load/unload valve at the unloading position. 1.6 Must have to inform to substation for running the compressor.

2 STARTING THE COMPRESSOR

2.1 Switch ON the main circuit breaker (MCCB). Then be sure that STAR DELTA motor starter is at ON position. Then set the Control supply ON/OFF switch at ON position in the operating panel board. 2.2 Press the start button (Green) and check the main motor rotation as per marked arrow on the motor. 2.3 Look at the panel board for following alarm signals; (a) Low lub oil pressure (b) Low cooling water flow (c) Motor over load.

3 SETTING TO THE WORK

3.1 Set load/unload valve at loading position. 3.2 After reaching working pressure open the air receiver tank out valve. 3.3 Start the Air Dryer as per Air Dryer SOP.

4 MONITORING DURING OPERATION OF THE COMPRESSOR

4.1 Monitor the indicators on the panel regularly. 4.2 Loading/ Unloading. 4.3 Drain condensate water regularly/ be sure that the auto drains system whether it works properly. 4.4 Record Starting time, loading time, unloading time.

5 STOPPING THE COMPRESSOR

5.1Press the stop button 5.2 Switch off the main circuit breaker. 5.3 Close all valves that you opened for starting.

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR RECIPROCATING COMPRESSOR 15T2/15T (WATER COOLED) 1BEFORE STARTING

1.1 Be sure that oil level of the frame (crank case) is in the workable level. 1.2 Be sure that water in the cooling tower is ok. 1.3 Turn on the all valves for circulation cooling water. 1.4 Switch ON the circulation pump and CT Fan. Be sure that water circulation by open manual valve on the 2nd stage compressor head. 1.5 Be sure that the receiver tank out valve is closed.

2 STARTING THE COMPRESSOR

2.1 Switch ON the main circuit breaker (MCCB). 2.2 Press the start button (Green) and check the main motor rotation as per marked arrow on the motor.

3 SETTING TO THE WORK

3.1 Be sure that loading and unloading is ok 3.2 After reaching working pressure open the air receiver tank out valve. 3.3 Start the Air Dryer as per Air Dryer SOP.

4 MONITORING DURING OPERATION OF THE COMPRESSOR

4.1 Monitor any abnormality during operation. 4.2 Loading/ Unloading. 4.3 Drain condensate water regularly/ be sure that the auto drains system whether it works properly.

5 STOPPING THE COMPRESSOR

5.1 Press the stop button 5.2 Switch off the main circuit breaker. 5.3 Close all valves that you opened for starting.

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR RECIPROCATING COMPRESSOR 15T2/15T (AIR COOLED) 1BEFORE STARTING

1.1 Be sure that oil level of the frame (crank case) is in the workable level. 1.2 Be sure that HE Tube/ Fined tube assembly is cleaned. 1.3 Be sure that the receiver tank out valve is closed.

2 STARTING THE COMPRESSOR

2.1 Switch ON the main circuit breaker (MCCB). 2.2 Press the start button (Green) and check the main motor rotation as per marked arrow on the motor.

3 SETTING TO THE WORK

3.1 Be sure that loading and unloading is ok 3.2 After reaching working pressure open the air receiver tank out valve. 3.3 Start the Air Dryer as per Air Dryer SOP.

4 MONITORING DURING OPERATION OF THE COMPRESSOR

4.1 Monitor any abnormality during operation. 4.2 Loading/ Unloading. 4.3 Drain condensate water regularly/ be sure that the auto drains system whether it works properly.

5 STOPPING THE COMPRESSOR

5.1 Press the stop button 5.2 Switch off the main circuit breaker. 5.3 Close all valves that you opened for starting.

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR REFRIGERANT AIR DRIER (AIR COOLED) 1BEFORE STARTING

1.1 Open air inlet & outlet valve and check air pressure flow. 1.2 Be sure that the condenser fan is OK & cleaned.

2 STARTING THE AIR DRIER

2.1 Switch ON the circuit breaker. 2.2 Press the start button (Green) and check the LP & HP pressure at workable level. 2.3 Check the dew point temperature on gauge panel.

4 MONITORING DURING OPERATION.

4.1 Monitor any abnormality during operation. 4.2 LP & HP of Refrigerant Gas. 4.3 Drain condenses water regularly/ be sure that the auto drain system whether it works properly.

5 STOPPING THE COMPRESSOR

5.1 Press the stop button 5.2 Switch off the main circuit breaker. 5.3 Close all valves that you have opened for starting

Sr.Engineer. (Utility)

Chief Engr. (PF)

SOP (U): 08.654

SOP FOR HYDROSTATIC TEST OF FIRE TUBE BOILER The following is a recommended procedure for hydrostatic testing; 1. Open the air purge brass ball valve which is on the steam drum. 2. Gagging the safety valve if impossible, remove the safety valves and replace with test plugs or blind flanges. 3.Close steam outlet valve (Main steam valve on boiler). 4. Close glove valve that is before the blow down valve. 5. Isolate pressure switches or other control components that are not intended to be subjected to a hydrostatic test. 6. Close gauge glass valve, pressure gauge valves. 7. Fill the boiler with treated water (water temperature 21 C to 48 deg C) and fill until water overflows the vent. 8. Apply pressure slowly. The recommended rate of pressure increase is less than 50 psi per minute. Raise pressure up to desired/test pressure ( 1.5 times of design pressure). 9. When the proper test pressure is reached, Inspection in accordance with the test objective can begin. Examine the system for any leaks. If no leaks are visible, Hold the system in a pressurized static condition for a period. 10. Upon completion of the test, release pressures slowly thoroughly a blow down valve.

Sr.Engineer. (Utility)

Chief Engr. (PF)