METHOD STATEMENT FOR STEAM BOILER BI-MONTHLY AND ANNUAL SERVICE

1. Scope

This method statement is for the Annual Steam Boiler Servicing of the [Numbers of the Boilers] located in [Mention here Area] & Client/company name. 

Before lifting any weight:

Warming up the muscles

Steam Boiler Bi-Monthly and Annual Service 

Before lifting any weight:

1. Warming up the muscles
2. Test the load
3. Plan the move

2. Personal

Boiler technician

Helper

3. Tool and Equipment

Assorted mechanical tools

Side Cutter

Multimeter

Flue gas analyzer

Tube cleaning equipment

4. Personal Protective Equipment (PPE)

The Personal Protective Equipment (PPE) as listed below has been developed & established to provide a Safe System of Work (SSOW) All our  employees/workers must utilize suitable Personal Protective Equipment (PPE) to prevent injuries and are accountable for complying with the provisions highlighted in this program. All employees/workers/workforce are expected to notify their supervisor when they feel one or more of their work tasks necessitate new or different PPE.

3 Layer Mask

Helmet

Safety Glasses

Leather and safety glove

Safety Shoe, Hi-visibility vest

Earplug

5. Prior Activities

Site visit

Approval from client

Obtain Permit to Work (PTW) from Concern & Related Department

Inspection by the Engineer and Supervisor

Provide suitable access

6. Procedure

This written document has been written to provide a safe system (SSOW) of work and must be adhered to at all times, any significant deviation from this system and must first be reviewed and authorized by the project manager or safety representative.

Bi-Monthly and Annual Steam Boiler Servicing:

The boiler shall be switched off before 3-days of scheduled and isolate the electrical power supply to avoid any electrical shock incident.

All staff to arrive at the worksite at the proper and correct time and location, wearing correct Personal Protective Equipment (PPE) 

All staff/workfoce to strictly abide by & follow the company safety procedures

Permit to Work (PTW) should be in place before starting any work

Switch off the boiler and close the principle steam valve, gasoline and water valves

Boilers will be inspected and observed carefully and closely before they are serviced to make sure that they are free of rust and other contamination.

Closely make a check for any steam, water, fuel leaks and repair before start of work.

Remove safety valve for calibration

Remove pressure gauge for calibration

Open the electrical panel and make a careful & closely inspect for any loose electrical connections and repair if required and necessary, and close the control panel door

Open burner and Check Flame Detectors (CFD's), seals and fuel nozzles are operating accurately and as intended.

Clean nozzles, close burner

Inspect and clean smoke tubes

Inspect and clean waterside

Check and observe very closely taht the refractory is in place and no damage or cracks are seen visually.

Blanking of all essential flanges for hydrostatic test

Fill the boiler with water.

Agree to test method with the Third-Party inspector.

Raise the water pressure to the 3rd party's inspector's requirement.

Maintain & intect the water pressure for a time allocated and agrred by the Third-Party inspector.

Following satisfactory and as required/standard hydrostatic test release the water pressure accordingly.

Remove all blanking plates.

Replace all removed equipment.

Remove Safety Relief Valve (SRV) and Pressure gauge for calibration, and reinstall after the calibration

Open major steam valve, gasoline and water valves again check for leaks

Make sure that all removed parts are fixed appropriately prior starting the boiler to check its performance.

Reconnect isolators for power supply

Set on boiler, and raise steam pressure gradually to 9-10 bars

Check safety interlocks for correct operation

Close water deliver line to check the operation of low degree and further low-stage water alarms

Remove Ultraviolet (UV) detector so boiler locks out on no flame detection

Increase strain at the boiler to test strain switches and protection valve operating efficiently

Install lance from combustion analyzer in exhaust chimney and take a look at combustion parameters for 02, excess air, CO.

Prepare service report and obtain counter signatory.

Handover original copy of the service report to the client/company.

7. Safety Procedure

First aid /Initial medical treatment facility shall be available for in site injuries and all injuries shall be reported to the responsible authority.

Any unusual incidents shall be brought to the notice of the responsible/accountable authorities.

All the areas shall be safeguarded and barricaded with warning tape to check abd stop the unauthorised entry into immediate working area.   

Well planned execution of work.

Safe use of tools and equipment.

Keep the extinguishing media close to the worksite.

8. Responsibilities

Forman and Supervisor (Company Name) will screen the continued web site activities, based on the accepted Method Statement and RA for every activity.

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