Standard Operating Procedure for Maintenance of Boilers

1) Purpose

The purpose of this SOP is to establish guidelines for the maintenance and operation of boilers in pharmaceutical manufacturing facilities to ensure safe and efficient steam production.

2) Scope

This SOP applies to all boilers used for steam generation within the facility premises.

3) Responsibilities

The Facilities Management Department is responsible for implementing and adhering to this SOP. The Boiler Technician is responsible for the maintenance and operation of boilers.

4) Procedure

1. Preventive Maintenance Schedule
   1. Develop a preventive maintenance schedule for boilers based on manufacturer recommendations and regulatory requirements.
   2. Perform regular inspections, cleaning, and maintenance tasks such as checking fuel levels, burner operation, water level, and pressure.
2. Boiler Startup and Shutdown Procedures
   1. Follow standard operating procedures for safely starting up and shutting down boilers.
   2. Monitor boiler parameters during startup and shutdown, including temperature, pressure, and fuel consumption.
3. Emergency Procedures
   1. Develop and maintain emergency procedures for boiler malfunctions, leaks, or other critical incidents.
   2. Train personnel on emergency response protocols and evacuation procedures if necessary.
4. Water Treatment and Testing
   1. Monitor boiler water quality and implement water treatment programs to prevent corrosion, scaling, and contamination.
   2. Regularly test boiler water for pH levels, conductivity, and dissolved solids.
5. Documentation and Reporting
   1. Maintain accurate records of boiler inspections, maintenance activities, water treatment, and testing results.
   2. Document any incidents, repairs, or adjustments made to the boiler system.

5) Abbreviations, if any

SOP: Standard Operating Procedure

6) Documents, if any

Preventive Maintenance Schedule, Boiler Inspection Reports, Emergency Procedures Manual, Water Treatment Logs

7) Reference, if any

National Fire Protection Association (NFPA) guidelines for boiler safety, manufacturer’s recommendations for boiler maintenance, and regulatory requirements for boiler operation.

8) SOP Version

Version 1.0