4BE3.5 U4 C4 Obj 1 EMH

Operator Rounds

• Before starting a shift, operators must have a handover discussion with the previous shift members, read the log book, and review log sheets to become familiar with the operating condition of all plant equipment.
• Operator rounds involve using all senses to assess the operating condition of the plant, including testing and formal log sheet entries.
• Rounds may be done by the shift engineer, assistant shift engineer, or both, and may take one to two hours to complete.

Boiler Plant Rounds

• The shift engineer usually performs the boiler plant rounds.
• Checks to be performed during boiler plant rounds include:
  • Water level: ensure the boiler water level is at set point (about half way up the gauge glass).
  • Blow down the water column, gauge glass, low water cut-offs, water feeders, feedwater flow transmitter, and drum level transmitter.
  • Steam pressure: ensure the main steam header pressure is normal and the boiler pressure is at or near set point.
  • Boiler firing rate: ensure the boiler firing rate varies with steam demand to maintain steam pressure at set point.
  • Boiler feed pumps: check for vibration, unusual noise, leaks, and discharge pressure.
  • Condensate receiver: check the level, pH, and hardness of the condensate.
  • Condensate transfer pumps: check for vibration, unusual noise, leaks, and discharge pressure.
  • Deaerator: ensure the deaerator water level is normal, and the deaerator vent valve is open.

Hot Water Boiler Plant Rounds

• Checks to be performed during hot water boiler plant rounds include:
  • Hot water temperature: ensure the boiler temperature is at or near set point.
  • Expansion tank: check the level of water in the expansion tank.
  • Circulating pumps: check for vibration, unusual noise, leaks, and discharge pressure.

Common Boiler Plant Rounds

• Checks to be performed during common boiler plant rounds include:
  • Boiler draft: check the furnace draft gauges and ensure the draft is correct.
  • Flue gas temperature: observe the flue gas temperature when the boiler is warmed up and firing.
  • Flame condition: ensure the flame is bright, free of soot, and does not impinge on any heat transfer surface.
  • Ventilation and combustion air supply: ensure the air openings into the boiler room are unobstructed.
  • Plant rounds: the assistant shift engineer usually conducts the plant rounds.

Air Compressor

• Checks to be performed during air compressor rounds include:
  • Pressure: ensure the compressed air pressure is at or near set point.
  • Blow off water from the base of the air receiver.
  • Cooling water flow: ensure adequate cooling water flow through the aftercooler.
  • Compressor lube oil pump pressure: ensure it is operating according to manufacturer's specifications.

Air Dryer

• Checks to be performed during air dryer rounds include:
  • Dew point: ensure the dew point is adequate according to the air dryer design and plant requirements.
  • Coalescing filter: ensure the pressure drop across the coalescing filter is not too great.

Standby Generator

• Checks to be performed during standby generator rounds include:
  • Battery charger: ensure the battery charger is working correctly.
  • Electrolyte levels: ensure the electrolyte levels in the batteries are adequate.
  • Block heater: ensure the block heater is operating and the engine is warm or hot.
  • Lube oil pressure and temperature: ensure they meet manufacturer specifications.

Housekeeping

• Overall housekeeping during routine rounds helps to promote a safe work environment.
• Checks to be performed during housekeeping rounds include:
  • Look for spills and leaks, and clean them up immediately.
  • Ensure chemicals are correctly stored and labelled.
  • Look for tripping hazards and return tools to their proper locations.
  • Assess lighting and report any areas that need replacement lamps.

Ongoing Maintenance

• Engineers must be aware of changing conditions due to ongoing power plant maintenance.
• Checks to be performed during ongoing maintenance rounds include:
  • Look for leaks and clean them up.
  • Be aware of tripping hazards created by drain hoses or power cords.
  • Check for open floor grates that were removed to facilitate maintenance.

Water Column Blowdown

• A water column blowdown should be completed at the beginning of every shift.
• The procedure for blowing down the water column includes:
  1. Isolate the water column.
  2. Blow down the water column.
  3. Place the water column back in service.
  4. Blow down the gauge glass.
  5. Place the gauge glass back in service.

Water Level Control

• Feedwater level controllers must be monitored regularly to ensure they maintain the boiler water level at set point.
• The procedure for testing the operation of the feedwater control valve includes:
  1. Close the isolation valve downstream of the feedwater valve.
  2. Observe changes in the valve position as the boiler level drops.
  3. Confirm that the feedwater control valve is responding correctly.
  4. Re-open the downstream isolating valve.
  5. Ensure the boiler water level returns to set point.

Steam Traps

• Steam traps should be observed for proper operation on a regular basis.
• The procedure for checking steam traps includes:
  1. Close the isolation valve downstream of the trap.
  2. Open a test valve located downstream of the trap.
  3. Observe steam flow from the test valve.
  4. If there is a constant flow of steam, the trap has failed.
  5. If there is intermittent condensate flow, the trap is functioning correctly.

Operator Rounds

• Before starting a shift, operators must have a handover discussion with the previous shift members, read the log book, and review log sheets to become familiar with the operating condition of all plant equipment.
• Operator rounds involve using all senses to assess the operating condition of the plant, including testing and formal log sheet entries.
• Rounds may be done by the shift engineer, assistant shift engineer, or both, and may take one to two hours to complete.

Boiler Plant Rounds

• The shift engineer usually performs the boiler plant rounds.
• Checks to be performed during boiler plant rounds include:
  • Water level: ensure the boiler water level is at set point (about half way up the gauge glass).
  • Blow down the water column, gauge glass, low water cut-offs, water feeders, feedwater flow transmitter, and drum level transmitter.
  • Steam pressure: ensure the main steam header pressure is normal and the boiler pressure is at or near set point.
  • Boiler firing rate: ensure the boiler firing rate varies with steam demand to maintain steam pressure at set point.
  • Boiler feed pumps: check for vibration, unusual noise, leaks, and discharge pressure.
  • Condensate receiver: check the level, pH, and hardness of the condensate.
  • Condensate transfer pumps: check for vibration, unusual noise, leaks, and discharge pressure.
  • Deaerator: ensure the deaerator water level is normal, and the deaerator vent valve is open.

Hot Water Boiler Plant Rounds

• Checks to be performed during hot water boiler plant rounds include:
  • Hot water temperature: ensure the boiler temperature is at or near set point.
  • Expansion tank: check the level of water in the expansion tank.
  • Circulating pumps: check for vibration, unusual noise, leaks, and discharge pressure.

Common Boiler Plant Rounds

• Checks to be performed during common boiler plant rounds include:
  • Boiler draft: check the furnace draft gauges and ensure the draft is correct.
  • Flue gas temperature: observe the flue gas temperature when the boiler is warmed up and firing.
  • Flame condition: ensure the flame is bright, free of soot, and does not impinge on any heat transfer surface.
  • Ventilation and combustion air supply: ensure the air openings into the boiler room are unobstructed.
  • Plant rounds: the assistant shift engineer usually conducts the plant rounds.

Air Compressor

• Checks to be performed during air compressor rounds include:
  • Pressure: ensure the compressed air pressure is at or near set point.
  • Blow off water from the base of the air receiver.
  • Cooling water flow: ensure adequate cooling water flow through the aftercooler.
  • Compressor lube oil pump pressure: ensure it is operating according to manufacturer's specifications.

Air Dryer

• Checks to be performed during air dryer rounds include:
  • Dew point: ensure the dew point is adequate according to the air dryer design and plant requirements.
  • Coalescing filter: ensure the pressure drop across the coalescing filter is not too great.

Standby Generator

• Checks to be performed during standby generator rounds include:
  • Battery charger: ensure the battery charger is working correctly.
  • Electrolyte levels: ensure the electrolyte levels in the batteries are adequate.
  • Block heater: ensure the block heater is operating and the engine is warm or hot.
  • Lube oil pressure and temperature: ensure they meet manufacturer specifications.

Housekeeping

• Overall housekeeping during routine rounds helps to promote a safe work environment.
• Checks to be performed during housekeeping rounds include:
  • Look for spills and leaks, and clean them up immediately.
  • Ensure chemicals are correctly stored and labelled.
  • Look for tripping hazards and return tools to their proper locations.
  • Assess lighting and report any areas that need replacement lamps.

Ongoing Maintenance

• Engineers must be aware of changing conditions due to ongoing power plant maintenance.
• Checks to be performed during ongoing maintenance rounds include:
  • Look for leaks and clean them up.
  • Be aware of tripping hazards created by drain hoses or power cords.
  • Check for open floor grates that were removed to facilitate maintenance.

Water Column Blowdown

• A water column blowdown should be completed at the beginning of every shift.
• The procedure for blowing down the water column includes:
  1. Isolate the water column.
  2. Blow down the water column.
  3. Place the water column back in service.
  4. Blow down the gauge glass.
  5. Place the gauge glass back in service.

Water Level Control

• Feedwater level controllers must be monitored regularly to ensure they maintain the boiler water level at set point.
• The procedure for testing the operation of the feedwater control valve includes:
  1. Close the isolation valve downstream of the feedwater valve.
  2. Observe changes in the valve position as the boiler level drops.
  3. Confirm that the feedwater control valve is responding correctly.
  4. Re-open the downstream isolating valve.
  5. Ensure the boiler water level returns to set point.

Steam Traps

• Steam traps should be observed for proper operation on a regular basis.
• The procedure for checking steam traps includes:
  1. Close the isolation valve downstream of the trap.
  2. Open a test valve located downstream of the trap.
  3. Observe steam flow from the test valve.
  4. If there is a constant flow of steam, the trap has failed.
  5. If there is intermittent condensate flow, the trap is functioning correctly.

Operator Rounds

• Before starting a shift, operators must have a handover discussion with the previous shift members, read the log book, and review log sheets to become familiar with the operating condition of all plant equipment.
• Operator rounds involve using all senses to assess the operating condition of the plant, including testing and formal log sheet entries.
• Rounds may be done by the shift engineer, assistant shift engineer, or both, and may take one to two hours to complete.

Boiler Plant Rounds

• The shift engineer usually performs the boiler plant rounds.
• Checks to be performed during boiler plant rounds include:
  • Water level: ensure the boiler water level is at set point (about half way up the gauge glass).
  • Blow down the water column, gauge glass, low water cut-offs, water feeders, feedwater flow transmitter, and drum level transmitter.
  • Steam pressure: ensure the main steam header pressure is normal and the boiler pressure is at or near set point.
  • Boiler firing rate: ensure the boiler firing rate varies with steam demand to maintain steam pressure at set point.
  • Boiler feed pumps: check for vibration, unusual noise, leaks, and discharge pressure.
  • Condensate receiver: check the level, pH, and hardness of the condensate.
  • Condensate transfer pumps: check for vibration, unusual noise, leaks, and discharge pressure.
  • Deaerator: ensure the deaerator water level is normal, and the deaerator vent valve is open.

Hot Water Boiler Plant Rounds

• Checks to be performed during hot water boiler plant rounds include:
  • Hot water temperature: ensure the boiler temperature is at or near set point.
  • Expansion tank: check the level of water in the expansion tank.
  • Circulating pumps: check for vibration, unusual noise, leaks, and discharge pressure.

Common Boiler Plant Rounds

• Checks to be performed during common boiler plant rounds include:
  • Boiler draft: check the furnace draft gauges and ensure the draft is correct.
  • Flue gas temperature: observe the flue gas temperature when the boiler is warmed up and firing.
  • Flame condition: ensure the flame is bright, free of soot, and does not impinge on any heat transfer surface.
  • Ventilation and combustion air supply: ensure the air openings into the boiler room are unobstructed.
  • Plant rounds: the assistant shift engineer usually conducts the plant rounds.

Air Compressor

• Checks to be performed during air compressor rounds include:
  • Pressure: ensure the compressed air pressure is at or near set point.
  • Blow off water from the base of the air receiver.
  • Cooling water flow: ensure adequate cooling water flow through the aftercooler.
  • Compressor lube oil pump pressure: ensure it is operating according to manufacturer's specifications.

Air Dryer

• Checks to be performed during air dryer rounds include:
  • Dew point: ensure the dew point is adequate according to the air dryer design and plant requirements.
  • Coalescing filter: ensure the pressure drop across the coalescing filter is not too great.

Standby Generator

• Checks to be performed during standby generator rounds include:
  • Battery charger: ensure the battery charger is working correctly.
  • Electrolyte levels: ensure the electrolyte levels in the batteries are adequate.
  • Block heater: ensure the block heater is operating and the engine is warm or hot.
  • Lube oil pressure and temperature: ensure they meet manufacturer specifications.

Housekeeping

• Overall housekeeping during routine rounds helps to promote a safe work environment.
• Checks to be performed during housekeeping rounds include:
  • Look for spills and leaks, and clean them up immediately.
  • Ensure chemicals are correctly stored and labelled.
  • Look for tripping hazards and return tools to their proper locations.
  • Assess lighting and report any areas that need replacement lamps.

Ongoing Maintenance

• Engineers must be aware of changing conditions due to ongoing power plant maintenance.
• Checks to be performed during ongoing maintenance rounds include:
  • Look for leaks and clean them up.
  • Be aware of tripping hazards created by drain hoses or power cords.
  • Check for open floor grates that were removed to facilitate maintenance.

Water Column Blowdown

• A water column blowdown should be completed at the beginning of every shift.
• The procedure for blowing down the water column includes:
  1. Isolate the water column.
  2. Blow down the water column.
  3. Place the water column back in service.
  4. Blow down the gauge glass.
  5. Place the gauge glass back in service.

Water Level Control

• Feedwater level controllers must be monitored regularly to ensure they maintain the boiler water level at set point.
• The procedure for testing the operation of the feedwater control valve includes:
  1. Close the isolation valve downstream of the feedwater valve.
  2. Observe changes in the valve position as the boiler level drops.
  3. Confirm that the feedwater control valve is responding correctly.
  4. Re-open the downstream isolating valve.
  5. Ensure the boiler water level returns to set point.

Steam Traps

• Steam traps should be observed for proper operation on a regular basis.
• The procedure for checking steam traps includes:
  1. Close the isolation valve downstream of the trap.
  2. Open a test valve located downstream of the trap.
  3. Observe steam flow from the test valve.
  4. If there is a constant flow of steam, the trap has failed.
  5. If there is intermittent condensate flow, the trap is functioning correctly.