[Virtual Presenter] The purpose of this presentation is to provide a comprehensive guide on the standard operating procedure for long-term preservation of MAXITHERM automatic packaged type D-shape water tube boilers. We will outline the essential steps to ensure the proper shutdown and preservation of these critical systems.. 

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Standard Operating Procedure (SOP) 
Long-Term Preservation of 
MAXITHERM Automatic Packaged 
Type D-Shape Water Tube Boiler

Scene 2

[Audio] The procedure for long-term preservation of the MAXITHERM automatic packaged type D-shape water tube boiler involves several steps. First, notify relevant personnel, including operators, maintenance staff, and other relevant departments, about the planned shutdown. Next, implement lock-out/tag-out procedures on the boiler, fuel system, and associated equipment. Gather all necessary tools and materials, such as silica gel, limestone, descaling agents, drying equipment, and protective covers. Then, gradually reduce the boiler's load to bring it to a safe operational state. Turn off the fuel supply, shut off the air supply to the burner system, close the feedwater valve, and stop the feedwater pump. Safely vent pressure from the boiler. Perform a complete blowdown by opening the blowdown valve to remove sludge, scale, and contaminants. Finally, de-energize the boiler, drain the water from the boiler, and inspect and clean the boiler. Apply preservation chemicals, such as silica gel for moisture control and limestone for corrosion protection, according to practical guidelines.. 

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Table of Content 
S No. 
Contents 
Page No. 
1 
2 
3 
4 
5 
5.1 
5.1.1 
5.1.2 
5.1.3 
5.2 
5.2.1 
5.2.2 
5.2.3 
5.3 
5.3.1 
5.3.2 
5.4 
5.4.1 
5.4.2 
5.5 
5.5.1 
5.5.2 
5.5.3 
5.5.4 
5.6 
5.6.1 
5.6.2 
5.6.3 
6 
6.1 
6.2 
7 
8 
9 
10 
 
Purpose 
Scope 
Responsibilities 
Required Tools and Materials 
Procedure 
Preparation and Safety Checks 
Notify Relevant Personnel 
Lock-Out/Tag-Out (LOTO) 
Gather Required Tools and Materials 
Shutdown Procedure 
Bring the Boiler to Safe Operational State 
Perform Complete Blowdown 
De-energize the Boiler 
Draining the Boiler 
Drain the Water from the Boiler 
Drain Associated Systems 
Inspection and Cleaning 
Perform Detailed Inspection 
Clean the Boiler 
Application of Preservation Chemicals 
Silica Gel for Water Side (Moisture Control) 
Practical Guidelines 
Limestone for Fire Side (Corrosion Protection) 
Practical Guidelines 
Securing the Boiler 
Close All Valves and Vents 
Seal and Protect Openings 
Dry the Boiler (if necessary) 
Documentation and Reporting 
Record All Actions Taken 
Notify Management and Maintenance 
Re-commissioning Procedure 
Safety Considerations 
References 
Revision History 
 
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2 
2 
2 
3 
3 
3 
3 
3 
3 
3 
3 
3 
3 
3 
4 
4 
4 
4 
4 
4 
5 
6 
6 
7 
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[Audio] This Standard Operating Procedure outlines the steps for the long-term shutdown of a MAXITHERM Automatic Packaged Type D-Shape Water Tube Boiler using the dry method with chemical preservation. The procedure covers the application of silica gel in the water side and limestone in the fire side to prevent corrosion and degradation during the shutdown period. Boiler Operators will implement the shutdown procedure, including draining, cleaning, and applying the chemical preservation methods. The Maintenance Team will ensure correct application of preservation chemicals and perform necessary inspections. Safety Personnel will ensure compliance with lock-out/tag-out procedures and other safety protocols. Supervisors/Managers will approve the procedure and ensure completion of all documentation. The required tools and materials include lock-out/tag-out devices, blowdown valve and pump, cleaning tools, silica gel, limestone, protective covers and seals, descaling agents, inspection tools, and drying equipment.. 

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2 
 
Standard Operating Procedure (SOP) 
Long-Term Shutdown of MAXITHERM Automatic Packaged Type D-Shape 
Water Tube Boiler Using Dry Method with Chemical Preservation 
1. Purpose 
This SOP outlines the procedure for the long-term shutdown of a MAXITHERM Automatic 
Packaged Type D-Shape Water Tube Boiler using the dry method, with specific details for 
the application of silica gel in the water side and limestone in the fire side to prevent corrosion 
and degradation during the shutdown period. 
2. Scope 
This procedure applies to the long-term shutdown of the MAXITHERM Automatic 
Packaged Type D-Shape Water Tube Boiler, covering the boiler’s water side and fire side. 
It includes the steps to drain, clean, apply preservation chemicals, and secure the boiler, as well 
as the required chemical calculations to ensure effective preservation during the idle period. 
3. Responsibilities 
• 
Boiler Operators: Implement the shutdown procedure, including draining, cleaning, 
and applying the chemical preservation methods (silica gel and limestone). 
• 
Maintenance Team: Ensure that all preservation chemicals are correctly applied, and 
perform necessary inspections. 
• 
Safety Personnel: Ensure compliance with lock-out/tag-out procedures and other 
safety protocols during the shutdown. 
• 
Supervisors/Managers: Approve the procedure and ensure that all documentation is 
completed. 
4. Required Tools and Materials 
• 
Lock-out/tag-out (LOTO) devices 
• 
Blowdown valve and pump 
• 
Cleaning tools (brushes, pressure washers) 
• 
Silica gel (for moisture control in the water side) 
• 
Limestone (for fire side preservation) 
• 
Protective covers and seals 
• 
Descaling agents (if needed) 
• 
Inspection tools (flashlights, magnifying glasses, gauges) 
• 
Drying equipment (air blowers or dehumidifiers)

[Audio] Before preparing the boiler for shutdown, it's crucial to notify relevant personnel, implement lock-out/tag-out procedures, and gather all necessary tools and materials. This preparation step ensures a safe and controlled environment for the shutdown process, thereby minimizing the risk of accidents and guaranteeing the boiler is properly prepared for shutdown.. 

Scene 5

5. Procedure 
5.1 Preparation and Safety Checks 
5.1.1 Notify Relevant Personnel 
• 
Inform all operators, maintenance staff, and relevant departments about the planned 
shutdown. 
5.1.2 Lock-Out/Tag-Out (LOTO) 
• 
Implement LOTO procedures on the boiler, fuel system, and all related equipment. 
5.1.3 Gather Required Tools and Materials 
• 
Ensure availability of all required tools and chemicals: silica gel, limestone, descaling 
agents, drying equipment, and protective covers. 
5.2 Shutdown Procedure 
5.2.1 Bring the Boiler to Safe Operational State 
• 
Gradually reduce load to bring the boiler to a steady state. 
• 
Turn off fuel supply (gas/oil). 
• 
Shut off air supply to the burner system. 
• 
Close the feedwater valve and stop the feedwater pump. 
• 
Safely vent pressure from the boiler. 
5.2.2 Perform Complete Blowdown 
• 
Open the blowdown valve to remove sludge, scale, and contaminants. 
• 
Perform a thorough blowdown according to manufacturer recommendations. 
5.2.3 De-energize the Boiler 
• 
Isolate all power sources and disconnect the automated control systems. 
5.3 Draining the Boiler 
5.3.1 Drain the Water from the Boiler 
• 
Open all drain valves and allow water to drain from the drum, tubes, and waterwalls. 
Ensure no water remains inside. 
 
5.3.2 Drain Associated Systems 
• 
Drain feedwater lines,  and other water-side components.

[Audio] The boiler preservation process requires inspecting and cleaning the boiler. A detailed examination of both internal and external components is performed to detect any signs of wear, corrosion, or damage. Affected areas are then cleaned using specialized equipment like brushes and pressure washers. Descaling agents might also be used to remove any hard deposits that have accumulated inside the boiler.. 

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4 
 
5.4 Inspection and Cleaning 
5.4.1 Perform Detailed Inspection 
• 
Inspect the internal and external components for any signs of wear, corrosion, or 
damage. 
5.4.2 Clean the Boiler 
• 
Clean the interior surfaces using brushes and pressure washers if needed. 
• 
Use descaling agents to remove any hard deposits inside the boiler. 
5.5 Application of Preservation Chemicals 
5.5.1 Silica Gel for Water Side (Moisture Control) 
Silica Gel Calculation for Water Side: 
• 
The purpose of silica gel is to absorb residual moisture from the water side of the boiler 
and prevent corrosion due to humidity. 
• 
The total volume of the water side (boiler’s flooded volume) is 8710 liters. 
Rule of Thumb:  
• For industrial boiler preservation, the general recommendation is 1.3 kg of silica gel 
per 1,000 liters of volume.  
1. Flooded Volume: 8710 liters 
2. Silica Gel Calculation: 
 
𝟖𝟕𝟏𝟎 𝐥𝐢𝐭𝐞𝐫𝐬
𝟏𝟎𝟎𝟎
× 𝟏. 𝟑𝐤𝐠 = 𝟏𝟏. 𝟑𝟐𝟑𝐤𝐠 
 
Result: 
Approximately 11 kg of silica gel is required.

[Audio] Silica gel should be distributed evenly throughout the boiler, particularly near areas prone to moisture accumulation such as the drum, headers, and other key locations. Mesh bags or trays should be used to allow air circulation and prevent silica from spilling out. Ensure that the bags are perforated to allow moisture absorption. Regular inspections should be conducted every 4-6 weeks to check for saturation. If using indicator silica gel, regeneration is possible through heating in anoven. Alternatively, replace the silica gel with fresh material if it cannot be regenerated or is too heavily saturated. Safety precautions include wearing gloves, using a dust mask, and disposing of silica gel according to local regulations.. 

Scene 7

5.5.2 Practical Guidelines 
1. Distribution: 
• 
Place silica gel in mesh bags or trays and distribute them inside the boiler, 
particularly near the drum, headers, and any other key areas prone to moisture 
accumulation. 
• 
Place silica gel in mesh bags or trays that allow air circulation. 
• 
Make sure the bags are perforated to allow moisture absorption but prevent the 
silica from spilling out. 
• 
Ensure even distribution for maximum effectiveness. 
2. Inspection: 
• 
Inspect silica gel every 4-6 weeks for saturation. Silica gel typically turns from 
blue to pink (in the case of indicator silica gel) when it is saturated with 
moisture. 
3. Regeneration Process: 
• 
If using indicator silica gel, once it becomes saturated, you can regenerate it by 
heating in an oven (at about 120-150°C for 1-2 hours). 
• 
Alternatively, replace the silica gel with fresh material if it cannot be regenerated or if 
it is too heavily saturated. 
4. Safety Precautions: 
• 
Always wear gloves when handling silica gel, especially if it contains indicators 
(such as cobalt chloride), which can be harmful if ingested or inhaled. 
• 
Use a dust mask to avoid inhaling fine silica particles when handling or 
transferring large quantities. 
• 
If silica gel cannot be regenerated and needs disposal, ensure that it is disposed 
of according to local regulations. Avoid flushing or dumping it directly into the 
environment. 
• 
Do not mix silica gel with other chemicals or substances unless specified by the 
manufacturer.

[Audio] Limestone calculation for fire side preservation requires us to determine the amount of limestone needed. The industry rule suggests that one kilogram of limestone is sufficient for every ten cubic meters of volume. In this case, we have two volumes: the combustion chamber volume, which measures 20.73 cubic meters, and the volume from the burner to the flue, which measures 33.52 cubic meters. To find the total fire side volume, we add these two values together, resulting in a total volume of 54.25 cubic meters. Based on the industry rule, we would require 5.42 kilograms of limestone. However, to be safe, we apply a safety factor of 1.5, which gives us a final requirement of approximately 8.07 kilograms of limestone.. 

Scene 8

6 
 
5.5.3 Limestone for Fire Side (Corrosion Protection) 
Limestone Calculation for Fire Side: 
Industry Rule of Thumb: 
For fire side preservation, use 1 kg of limestone per 10 m³ of volume. 
1. Combustion Chamber Volume: 20.73 m³ 
2. Volume from Burner to Flue: 33.52 m³ 
3. Total Fire Side Volume: 
 
 
                                                  𝟐𝟎. 𝟕𝟑 𝐦𝟑 + 𝟑𝟑. 𝟓𝟐 𝐦𝟑 = 𝟓𝟒. 𝟐𝟓 𝐦𝟑 
Limestone Calculation:                
                                                  
𝟓𝟒.𝟐𝟓 𝐦𝟑
𝟏𝟎 𝐦𝟑 × 𝟏 𝐤𝐠 = 𝟓. 𝟒𝟐𝟓 𝐤𝐠 
Applying Safety Factor of 1.5: 
 
                                                   𝟓. 𝟒𝟐𝟓 𝐤𝐠 × 𝟏. 𝟓 = 𝟖. 𝟏𝟑𝟕 𝐤𝐠 
Result: 
Approximately 8 kg of limestone is required. 
 
5.5.4 Practical Guidelines 
5. Distribution: 
• 
Place the limestone in open trays or bags along the combustion chamber and 
flue path. 
• 
Ensure even distribution for maximum effectiveness. 
6. Inspection: 
• 
Check the limestone every 4-6 weeks. 
• 
Replace if it turns into a powdery form (indicating moisture absorption). 
7. Safety Precautions: 
• 
Wear gloves, goggles, and a mask when handling limestone. 
• 
Avoid inhaling dust, and store limestone in a dry location.

[Audio] Secure the boiler by closing all valves, vents, and drain ports. Next, use protective covers to seal manholes, inspection ports, and other openings to prevent the entry of moisture or contaminants. If necessary, utilize air blowers or dehumidifiers to dry the boiler before sealing. Following this, document all actions taken, including chemical usage, and inform management and maintenance that the boiler has been successfully shut down and preserved. Moreover, guarantee that the surrounding area is well-ventilated throughout the shutdown.. 

Scene 9

5.6 Securing the Boiler 
5.6.1 Close All Valves and Vents 
• 
Securely close all valves, vents, and drain ports. 
5.6.2 Seal and Protect Openings 
• 
Use protective covers to seal manholes, inspection ports, and other openings to prevent 
the entry of moisture or contaminants. 
5.6.3 Dry the Boiler (if necessary) 
• Use air blowers or dehumidifiers to ensure the boiler is thoroughly dry before sealing. 
 
6. Documentation and Reporting 
6.1 Record All Actions Taken 
• 
Document all steps in the shutdown process, including chemical usage (silica gel and 
limestone). 
6.2 Notify Management and Maintenance 
• 
Inform management and the maintenance team that the boiler has been successfully 
shut down and preserved. 
 
7. Re-commissioning Procedure 
When the boiler is ready to be started again: 
• 
Inspect the boiler for any damage or degradation. 
• 
Remove silica gel and limestone from the boiler before re-commissioning. 
• 
Test all systems (feedwater, fuel supply, etc.) to ensure proper operation. 
8. Safety Considerations 
• 
Always follow lock-out/tag-out (LOTO) procedures. 
• 
Use proper PPE when handling chemicals like silica gel and limestone. 
• 
Ensure the area around the boiler is well-ventilated during the shutdown.

[Audio] The references used in this procedure are the MAXITHERM Boiler Manufacturer's manual, plant standard operating procedures, and guidelines from the Occupational Safety and Health Administration for boiler safety and chemical handling. These resources provide essential information for ensuring the safe and effective preservation of the MAXITHERM automatic packaged type D-shape water tube boiler.. 

Scene 10

8 
 
9. References 
• 
MAXITHERM Boiler Manufacturer’s Manual 
• 
Plant Standard Operating Procedures (SOP) 
• 
OSHA Guidelines for Boiler Safety and Chemical Handling 
 
10. Revision History 
Version 
Date 
Description 
Approved By

Sop of Boiler Preservation 12-12-2024

The procedure for long term preservation of the maxitherm automatic packaged type D-shape water tube boiler involves several steps. First, notify relevant personnel, including operators, maintenance staff, and other relevant departments, about the planned shutdown. Next, implement lock out/tag out procedures on the boiler, fuel system, and associated equipment. Gather all necessary tools and materials, such as silica gel, limestone, descaling agents, drying equipment, and protective covers. Then, gradually reduce the boiler's load to bring it to a safe operational state. Turn off the fuel supply, shut off the air supply to the burner system, close the feedwater valve, and stop the feedwater pump. Safely vent pressure from the boiler. Perform a complete blowdown by opening the blowdown valve to remove sludge, scale, and contaminants. Finally, de energize the boiler, drain the water from the boiler, and inspect and clean the boiler. Apply preservation chemicals, such as silica gel for moisture control and limestone for corrosion protection, according to practical guidelines.

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This Standard Operating Procedure outlines the steps for the long term shutdown of a maxitherm Automatic Packaged Type D-Shape Water Tube Boiler using the dry method with chemical preservation. The procedure covers the application of silica gel in the water side and limestone in the fire side to prevent corrosion and degradation during the shutdown period. Boiler Operators will implement the shutdown procedure, including draining, cleaning, and applying the chemical preservation methods. The Maintenance Team will ensure correct application of preservation chemicals and perform necessary inspections. Safety Personnel will ensure compliance with lock out/tag out procedures and other safety protocols. Supervisors/Managers will approve the procedure and ensure completion of all documentation. The required tools and materials include lock out/tag out devices, blowdown valve and pump, cleaning tools, silica gel, limestone, protective covers and seals, descaling agents, inspection tools, and drying equipment.

Before preparing the boiler for shutdown, it's crucial to notify relevant personnel, implement lock out/tag out procedures, and gather all necessary tools and materials. This preparation step ensures a safe and controlled environment for the shutdown process, thereby minimizing the risk of accidents and guaranteeing the boiler is properly prepared for shutdown.

The boiler preservation process requires inspecting and cleaning the boiler. A detailed examination of both internal and external components is performed to detect any signs of wear, corrosion, or damage. Affected areas are then cleaned using specialized equipment like brushes and pressure washers. Descaling agents might also be used to remove any hard deposits that have accumulated inside the boiler.

Silica gel should be distributed evenly throughout the boiler, particularly near areas prone to moisture accumulation such as the drum, headers, and other key locations. Mesh bags or trays should be used to allow air circulation and prevent silica from spilling out. Ensure that the bags are perforated to allow moisture absorption. Regular inspections should be conducted every 4-6 weeks to check for saturation. If using indicator silica gel, regeneration is possible through heating in anoven. Alternatively, replace the silica gel with fresh material if it cannot be regenerated or is too heavily saturated. Safety precautions include wearing gloves, using a dust mask, and disposing of silica gel according to local regulations.

Limestone calculation for fire side preservation requires us to determine the amount of limestone needed. The industry rule suggests that one kilogram of limestone is sufficient for every ten cubic meters of volume. In this case, we have two volumes: the combustion chamber volume, which measures 20.73 cubic meters, and the volume from the burner to the flue, which measures 33.52 cubic meters. To find the total fire side volume, we add these two values together, resulting in a total volume of 54.25 cubic meters. Based on the industry rule, we would require 5.42 kilograms of limestone. However, to be safe, we apply a safety factor of 1.5, which gives us a final requirement of approximately 8.07 kilograms of limestone.

Secure the boiler by closing all valves, vents, and drain ports. Next, use protective covers to seal manholes, inspection ports, and other openings to prevent the entry of moisture or contaminants. If necessary, utilize air blowers or dehumidifiers to dry the boiler before sealing. Following this, document all actions taken, including chemical usage, and inform management and maintenance that the boiler has been successfully shut down and preserved. Moreover, guarantee that the surrounding area is well ventilated throughout the shutdown.

The references used in this procedure are the maxitherm Boiler Manufacturer's manual, plant standard operating procedures, and guidelines from the Occupational Safety and Health Administration for boiler safety and chemical handling. These resources provide essential information for ensuring the safe and effective preservation of the maxitherm automatic packaged type D-shape water tube boiler.