WORK METHODOLOGY

(STEP BY STEP WORK PROCEDURES)

Project Boiler Troubleshooting and Maintenance

Project Start Date December 11, 2021
Expected Duration 3 weeks
Projected Completion Date January 1, 2022
No. of Technicians 3
No. of Plant Personnel 3
No. of Plant Engineers 1
No. of Safety Representative 1

Brand Name : CLEAVER-BROOKS MODEL CB (125 through 200 HP)

Fuel : Light Oil, Heavy Oil, Gas or Combination

Figure 1. Cleaver-Brooks Boiler Model

INTRODUCTION

Accidents do happen. This basic observation is the basis for innumerable standards,
guidelines, laws, procedures, and work norms that have shaped the present landscape of safe
practices and installations across industry. Adherence to existing safety guidelines prevents the
great majority of incidents because, while accidents do occur, the vast majority are avoidable.
Thus, even when the plant is not in operation, it is vital for the operator to be aware of any
anomalous situations or circumstances and to communicate effectively with personnel in order to
resolve such difficulties, (Palmer, 2005).
Among the boiler issues that must be addressed are shutdowns that occur during firing.
Another issue with the boiler is that the modulating motor does not work. Finally, there have
been reports of the burner remaining on low fire, (Cleaver-Brooks Division of Aqua-Chem Inc.,
1998).
This work methodology was established to offer a safe system of work and must be
followed at all times; any substantial variation from this system must first be allowed by the
management or safety representative. Before commencing the procedure, please read the full
document; if you have any questions, please contact a safety representative.

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SAFETY MANAGEMENT

The goal of safety and risk management is to lay the groundwork for a fair allocation of
resources among all evaluated safety risks and those safety risks whose control and mitigation
are feasible. As a result, safety risk management is an essential component of the safety
management process, (De Florio, 2011).

PERSONAL PROTECTIVE EQUIPMENT TO BE WORN

• hard hat
• heavy-duty work gloves
• eye protection goggles
• coveralls

PRECAUTIONS TO BE TAKEN

• While doing boiler repair, it is critical to wear a helmet.

• Before ascending the boiler, make sure that no oil has spilled around it.
• Only do maintenance when there is enough light inside the boiler.
• While climbing on the boiler, make sure the scaffolding is strong and solid.
• There is a danger of knee damage if you hit the Drum Internals when getting down in the
stream drum. As a result, first thoroughly comprehend the welded areas of the drum
before entering it for inspection. Take appropriate eye and head protection.
• Before descending down in the Steam Drum / Water Drum, open the manhole and inspect
the interior of the drum. There is a potential of dogs, snakes, or honeybees living within
the bottom portion of the Lancashire boiler or an external boiler furnace.
• Check that the blow down of all boilers in the battery is not connected together.
• Ascertain that the feed water pump's fuse has been removed. Only when the boiler has
been disconnected from the battery of boilers may maintenance be performed.
• When entering the boiler for maintenance, check to see if the burner fuse has been
removed, whether in a small or large oil-fired boiler, and then do maintenance/inspection.

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BOILER ISSUES TO BE ADDRESSED

1. Shutdown occurs during firing

2. Modulating motor does not operate
3. Burner stays in low fire

TASKS FOR BOILER MAINTENANCE

1. Clean fireside surfaces and breeching

2. Inspect waterside surfaces
3. Check operation of safety valves

TIME SCHEDULE AND TASK ASSIGNMENT

Date Task Assigned

Technician 1 and Plant
December 11-17, 2021 Troubleshooting of BOILER ISSUE NO. 1
Personnel 1
Technician 2 and Plant
December 18-24, 2021 Troubleshooting of BOILER ISSUE NO. 2
Personnel 2
Technician 3 and Plant
December 26-31, 2021 Troubleshooting of BOILER ISSUE NO. 3
Personnel 3
All Technicians and
January 1, 2022 Boiler maintenance
Plant Personnel

NOTE:

The PLANT ENGINEER and the SAFETY REPRESENTATIVE are required to accompany
the technicians and plant personnel during the whole project duration.

MANPOWER DELINEATION

Plant Engineer – in-charge of planning, designing, and supervising the project

Safety Representative – assesses the risk and hazards and ensures the safety of the workers;
knowledgeable about first aid treatment and etc.

Technician – pilots the tasks in troubleshooting the issues of the boiler; in-charged of
disassembly and reassembly.

Plant Personnel – assists the technicians and reports the significant issues of the boiler.

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TROUBLESHOOTING GUIDE

WARNING
Trouble shooting should be performed only by personnel who are familiar with the
equipment and who have read and understand the contents of this methodology. Failure to follow
these instructions could result in serious personal injury or death
Disconnect and lock out the main power supply in order to avoid the hazard of electrical
shock. Failure to follow these instructions could result in serious personal injury or death

BOILER ISSUE NO. 1

Problem Possible Causes
1. Loss or stoppage of fuel supply.
2. Defective fuel valve; loose electrical connection.
3. Flame detector weak or defective.
4. Lens dirty or sight tube obstructed.
5. If the programmer lockout switch has not tripped,
check the limit circuit for an opened safety control.
6. If the programmer lockout switch has tripped:
Shutdown occurs during firing
• Check fuel lines and valves
• Check flame detector
• Check for open circuit in running interlock
circuit
• The flame failure light is energized by
ignition failure, main flame failure,
inadequate flame signal, or open control in
the running interlock circuit.

BOILER ISSUE NO. 2

Problem Possible Causes
1. Manual-automatic switch in wrong position.
2. Linkage loose or jammed.
3. Motor does not drive to open or close during pre-
purge or close on burner shutdown.
• Motor defective.
• Loose electrical connection.
Modulating motor does not operate • Damper motor transformer defective.
4. Motor does not operate on demand.
• Manual/automatic switch in wrong position.
• Modulating control improperly set or
inoperative.
• Motor defective.
• Loose electrical connection.
• Damper motor transformer defective.

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BOILER ISSUE NO. 3
Problem Possible Causes
1. Pressure or temperature above modulating control
setting.
Burner stays in low fire 1. Manual-automatic switch in wrong position.
2. Inoperative modulating motor.
3. Defective modulating control.
4. Binding or loose linkage, cams, setscrews, etc.

MAINTENANCE GUIDE
WARNING
Disconnect and lock out electrical power and fuel to the boiler before opening either the
front or rear head. Failure to follow these instructions can result in electrical shock and serious
personal injury or death.
1. Clean fireside surfaces and breeching
Because an accumulation of soot deposits raises the flue gas temperature, a stack
temperature thermometer can be utilized as a guide to clean-out intervals. Opening the front and
rear doors allows for tube cleaning (see Figure 1). Brushing tubes can be done from either end.
Ensure that any loose soot and accumulations are removed. Any soot or other deposits on the
furnace and tube sheets should be removed.
When opening the front head, either remove the motor and fan cassette assembly or
swing the assembly away from the head. Alternatively, with the motor and cassette in place,
remove the motor to davit arm connection bolt to allow swinging the motor and fan cassette with
the head.
Disconnect the fuel lines after ensuring that the electrical power and gasoline are both
turned off (see Figure 2). Disconnect the main gas line coupling, the pilot line, and the sight port
air line. If the boiler is oil-fired, disconnect the supply and return oil lines, as well as the oil pilot
line, if necessary. Remove the head bolts and swing the head.
To avoid any deformation of the head or hinge area, the open head should be maintained
by blocking or jacking.
Check all gaskets and sealing surfaces before closure. The door gasket should be changed
if it is hard or brittle. It is not recommended that the fiberglass ropes be reused. The baffle seal's
head flange and tube sheet areas should be clean and free of old sealing material, scale, and other
debris. Ensure that all of the gasket retention fasteners are securely fastened.

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 Remove the old rope from the baffle tile or refractory, as well as the insulating cement.
Make sure the refractory doesn't get chipped or cracked. The rope is inserted in the groove of the
monolithic design and on top of the lip of the tile baffle type construction while closing the rear
head.

Figure 2 Figure 3
Open Front and Head Inner Door Disconnect Fuel lines and Sight Glass Cooling Tube

2. Inspect waterside surfaces

Always keep an eye on the water level in the boiler. The water column in steam boilers
should be blown down on a daily basis.
Because the point of low water cutoff and the point of pump cut-in or cut-out are usually
set by the original manufacturer, no attempt should be made to adjust these controls to change
the point of low water cutoff or the point of pump cut-in or cut-out.
• Steam Boiler
The head mechanism of the low water cutoff device(s) on a steam boiler should
be removed from the bowl at least semi-annually to examine and clean the float ball,
internal working components, and bowl or water column.
Remove the pipe plugs from the tees or crosses and inspect the cross-connecting
piping for cleanliness and blockages. For effective functioning, controls must be placed
plumb. Ascertain that the pipe is vertically aligned following shipping and installation, as
well as during the life of the equipment.
• Hot Water Boiler
Remove the operating mechanism from the bowl at least once a year, preferably
more frequently, to inspect and clean the float ball, internal moving components, and
bowl housing. Check the cross-connecting pipe as well to ensure that it is clean and free
of obstructions.
3. Check operation of safety valves
The safety valve is a critical safety device that requires special care. Excessive use of the
safety valve should be avoided; even a single opening might result in a leak. Only use safety
valves as needed to ensure that they are in proper working order. When a pop test is necessary,
increase the working pressure to the safety valve's set pressure, enabling it to open and reseat
normally

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 Apply no less than 75% of the stamped set pressure to the disc's underside while hand-
operating the valve. If you're shutting the valve by hand, make sure you keep it open long
enough to eliminate any accumulated foreign material from the seat region.
The seat and disc of the safety valve will get wire drawn or steam cut if it is used often.
This will cause the valve to leak, resulting in boiler downtime while the valve is repaired or
replaced. A valve may only be repaired by the manufacturer or his authorized agent.
Avoid operating pressures that are too close to the safety valve set pressure. A ten percent
difference is suggested. A larger differential is preferable because it ensures higher seat tightness
and valve life.

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References
Cleaver-Brooks Division of Aqua-Chem Inc. (1998). CB-LE Packaged Boiler 125 through 200
HP Fuel: Light Oil, Heavy Oil, Gas or Combination Operation, Service, and Parts
Manual.

De Florio, F. (2011). Continued Airworthiness and Operation. Airworthiness, 243–319.

https://doi.org/10.1016/b978-0-08-096802-5.10009-1

Palmer, J. A. (2005). The Roles of Operations, Maintenance, and Management in a Preventable

Power Plant Explosion. ASME 2005 Power Conference, 41820, 363–366.
https://doi.org/10.1115/pwr2005-50164

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List of Figures

Figure 1. Cleaver-Brooks Boiler Model (Page 1)

Figure 2. Open Front and Head Inner Door (Page 6)
Figure 3. Disconnect Fuel lines and Sight Glass Cooling Tube (Page 6)