Basic & Intermediate Boilers Training Course

3/11/2008DTW Designs (QLD) Pty Ltd1

Basic & Intermediate Boiler Basic & Intermediate Boiler Training CourseTraining Course

Owen BrischkeDTW Designs (Qld) Pty Ltd

RTO # 31507


Introduction Introduction

This course will provide participants with an understanding of the design, purpose and operation of Basic & Intermediate Boilers in common use in small Industrial Plants.Trainees will gain underpinning knowledge in plant theory and WHS considerations associated with Basic & Intermediate Boilers.


AgendaAgendaThe topics to be covered will include:– An overview of NOHSC 1006 (2001) and Boiler

Classifications, WHSQ and Australian Standards 3873 (2001) & 2593 (2004)

– Registered Training Organisations, Employers & Trainees

– Unattended and Limited Attendance Boilers– Attended Boilers– Boilers and their Principal Parts– Boiler Start, Shutdown and Emergencies


Topic One Topic One –– NOHSC NOHSC ClassificationsClassifications

Australian Safety & Compensation Council (ASCC) formerly NOHSC is responsible for setting the guidelines for the safe operation of Pressure EquipmentWHS Qld is responsible for managing registration and operator certificationAn example is defining Basic, Intermediate and Advanced Boilers and the Competencies required to operate themWould you expect ASCC to define Unattended Boilers?


Topic Two Topic Two –– Registered Training Registered Training Organisations (RTOs) Employers Organisations (RTOs) Employers & Trainees& Trainees

An RTO provides the training and assessment services and has specific responsibilities.The Employer provides the worksite and plant and has specific responsibilities in relation to plant and trainees.Trainees receive the training and assessment and have specific responsibilities.


Topic Three Topic Three –– Unattended and Unattended and Limited Attendance BoilersLimited Attendance Boilers

Unattended and Limited Attendance Boilers have been designed for reduced Operator AttendanceAre you aware of any sites with an Unattended Boiler?


Unattended Boiler DefinitionUnattended Boiler Definition

A boiler designed for fully automatic operation with fail - safe features and suitable for periods of operation without human supervision, subject to regular checks by a trained person and subject to specified supervision and maintenance procedures.


Limited Attendance BoilerLimited Attendance Boiler

A boiler designed for fully automatic operation with fail - safe features and suitable for periods of operation without human supervision, subject to regular checks by a certificated boiler attendant and subject to approved supervision and maintenance procedures.


Operation as Unattended to Operation as Unattended to AS2593AS2593

Unattended if it has a design pressure 2.5 MPa Max and – Is a Water Tube Steam Boiler - 10 MW Maximum – Is any type of Hot Water Boiler - 10 MW Maximum – Is an Electrode or Electric Element type- Some

limitations apply. – Is a small “Low Hazard” boiler 500 kW Maximum


Operation as Limited Attended to Operation as Limited Attended to AS2593AS2593

Limited Attended if it has a design pressure 2.5 MPa Max and– Is a Water Tube Steam Boiler - 20 MW

Maximum – Is any type of Hot Water - 20 MW Maximum – Is any other type - 5 MW Maximum


Differences between Unattended & Differences between Unattended & Limited Attended OperationLimited Attended Operation

Water Tube Steam and Hot Water Boilers 10 MW Unattended - 20 MW Limited Attended Any Type of Boiler can Operate Limited Attended to 5 MW


Differences between Unattended & Differences between Unattended & Limited Attended OperationLimited Attended Operation

Unattended supervised at 24 hr intervals by a trained person Limited Attended supervised at 4hr or 12 hr intervals by a certificated person Attended boilers must be supervised continuously by a certificated person


Attended Boiler Control PhilosophyAttended Boiler Control Philosophy

Attended Boiler Philosophy assumes that the Boiler Attendant can safely identify and correct a potentially dangerous situation before it becomes hazardous. Automatic Controls are considered an aid to the human supervisory function Humans are not well suited to this form of supervision.


Unattended /Limited Attended Unattended /Limited Attended Boiler Control PhilosophyBoiler Control Philosophy

The Unattended Boiler Philosophy is to specifically exclude human involvement, as far as is practical. The Safety of the Boiler is entrusted to Safety Control Systems using “Fail Safe” principles and Dynamic Self Checking Devices. Automatic Controls are well suited to this form of supervision.


Unattended Boilers Dynamic Self Unattended Boilers Dynamic Self Checking Devices are Applied ToChecking Devices are Applied To

Flame Supervision - UV Detectors Water Level Security. PLC Operation - External timers with feed back to the PLC, if used.


Topic Four Topic Four –– What is a Boiler?What is a Boiler?

A vessel or an arrangement of vessels and interconnecting parts, wherein steam or other liquid is heated at a pressure above that of the atmosphere by the application of fire, the products of combustion, electrical power or similar means.– It also includes valves, gauges, fittings,

controls, the boiler setting and directly associated equipment.


Principal Parts of a BoilerPrincipal Parts of a Boiler

Furnace – Energy ConversionHeating Surfaces – Absorption of Heat from the FurnaceSteam/Water Separators – Separate Water from SteamFeedwater Supply – Provides the Water as the working medium for conversion to steamDraft Equipment – Fans for supplying air for combustion and removal of flue gasFuel Supply – Provides the energy sourceControl Equipment – Controlling Start, Operation, Shutdown and Safe Tripping of Plant


Boiler MountingsBoiler MountingsBoiler Mountings are attached devices which perform specific tasks associated with the Boiler.They may include:– Safety Valves and Escape Pipework – Maintain Safe

Operating Pressure– Water Level Control Devices – Control Water Level

to Setpoint– Water Level Indication Devices – Provide

confirmation of Water Level– Pressure Gauges – Indicate Boiler Pressure


Boiler MountingsBoiler Mountings– Boiler Stop Valve – Provide Isolation of

Steam Supply– Boiler Vent Valve – Allow for Venting of Air

on Filling and Emptying– Blowdown Valves – Water Quality Control

through Blowdown– Expansion System – To allow safe expansion

and contraction of the Boiler– Explosion Doors/Discs – Minimise damage in

the event of explosion


Typical BoilersTypical Boilers

Fire Tube Boiler



Fire Tube Boiler Section



Water Tube Boiler Section



Water Tube Boiler Section


Water Tube Boiler CirculationWater Tube Boiler Circulation


Enthalpy CurveEnthalpy Curve


Feedwater SystemFeedwater System

A typical Feedwater System comprises the following:– Incoming Supply –Town or Raw Water– Water Conditioning Plant –Water Softening Plant or

Demineraliser– Feedwater Tank – May include a Preheater– Feedwater Pumps– Feedwater Control Valve and Isolation Valves– Chemical Injection System – Added Chemicals condition the

feedwater– Feedwater Sampling Point– Blowdown Valve/s


Draft SystemDraft System

A typical Draft System comprises the following:– Air Intake– Forced Draft Fan – Supplies Combustion Air (may

also force flue gases from the Boiler if no Induced Draft Fan

– Induced Draft Fan – Maintains a negative pressure in the furnace and removes flue gases (May not be fitted to all boilers)

– Damper Control to Regulate Air Flow & Isolate Air and Gas Systems


Fuel SystemFuel SystemA typical Fuel System comprises the following:– Gas Supply Line with Isolation Valves– Gas Block and Bleed Valves – Ensure Safe isolation and venting

of Fuel Supply Line on Boiler Trip– Pressure Reducing Station – To reduce supply pressure to

working pressure– Pressure Modulating Valve– Pressure Monitoring Devices – To ensure Pressure Reducing

Station correct operation– Ignition device – to ignite the fuel– Flame Scanner – to monitor the flame and shutdown the boiler in

event of flame failure


Control SystemControl System

A typical Control System comprises the following:– A Programmable Logic Controller – for

setting the Control System Parameters and Monitoring the Processes

– Control and Monitoring Devices for measuring and setting operating conditions

– Operator Interface allowing Operator Intervention when necessary


Control SystemControl SystemA typical Feedwater Level Control System


Topic Five Topic Five –– Typical Maxitherm Typical Maxitherm Boiler and Associated EquipmentBoiler and Associated Equipment

A Typical Boiler and Associated Equipment consists of:– 6MW Maxitherm 2 Drum Watertube Boiler– Water Softener with Brine Tank– Feedwater Preheater– Feedwater Tank– 2 Boiler Feedwater Pumps– Feedwater Control Valve and Bypass Valve– Chemical Injection Pumps and Tanks– Blowdown Valve and Blowdown Tank– Boiler Main Stop Valve and Steam System to the Factory– Fuel Gas System– Forced Draft Air System– PLC and Associated Operator Interface


Boiler Single Line DiagramBoiler Single Line Diagram


Gas SupplyGas Supply

Main Gas Isolation Valve

Pilot Gas Isolation Valve

Flow Measurement

Main Pressure Reducer

Pilot Pressure Reducer


Gas SupplyGas Supply

Block Valves

Bleed Valve

High Gas Pressure Switch


Burner FrontBurner Front

Pilot Gas Supply

Pilot Air Supply

Igniter Transformer

Pilot Gas Supply Block Valves and Pressure Switches

Igniter

Flame Detectors


Burner FrontBurner Front

Fuel Gas and Air Supply Regulator Gas Regulator

Valve

Air Supply Damper

Low Gas Pressure Switch


Softener and ChemicalsSoftener and Chemicals

Chemical Drums

Chemical Pumps

Water Softener


BoilerBoiler

Feed Line to Feed Pumps

Feed Pump Motors & Controls

Feedwater Control Valve


BoilerBoiler

Main Boiler Stop Valve

Drum Vent Valve

Drum Safety Valves

Drum Level Control and Indication Probes

Flue Gas Stack

Pressure Gauge


Heat ExchangerHeat Exchanger

Feedwater Preheater

Flue Gas to Feedwater Preheater


Feed PumpsFeed Pumps


Feedwater Control ValveFeedwater Control Valve


Maintenance SuppliersMaintenance Suppliers

Chemical Supplies and Water Treatment– Drew Australia Pty Ltd

Phone 3633 0277

Boiler Maintenance– Tomlinson Boilers Pty Ltd

Phone 3375 1360


Preparation for StartPreparation for Start--UpUp

Work Area Clean and TidyAll Lighting ServiceableTown Water AvailableGas Supply AvailablePower AvailablePLC AvailableOperator Interface Available


AlarmsAlarms

Alarms are displayed on the Alarm Screen of the Operator Interface ComputerAlarms should first be silenced, then read and acknowledged before rectifying the faultOnce the fault is rectified the alarm should be cleared


AlarmsAlarms

To Silence Alarms – Press MUTE on control panel.After an alarm condition has been rectified, press RESET to start Boiler if required.


Boiler StartBoiler Start--UpUpIt is normal to check and set up the systems before

firing. The following is a basic process.1. Open Feedwater Isolation Valve2. Open Boiler Gas Main and Bypass Inlet

Isolation Valves3. Check Gauge Glasses are in service and water

level is within limits4. Check the Boiler Pressure and if it is

0 kPa then Open the Vent Valve on the Boiler Drum


Boiler StartBoiler Start--UpUp

5. If water level is low, top up water level (See step 6)

6. Switch the Feedwater Control Switch on the Motor Control Centre to FILL

7. Press RESET, the Feed Water Pumps will start and the Boiler will fill.



8. Once the water level is over half way on the gauge glass, turn the switch on the left from Fill to AUTO.

9. Switch the Burner On/Off switch on the far right to ON. The Forced Draft Fan will start and the Purge Cycle will commence.



10. Once the Purge is complete the Burner will now start up automatically and hold at Low Fire until the pressure reaches 140 kPa.

11. Shut the Vent Valve on the Steam Drum on top of the boiler



12. When pressure reaches 400 kPa Open the Boiler Main Steam Stop Valve (Very, very slowly)

13. Open the Auto Blowdown Valve.14. Walk and Check the Steam Supply

Pipework and ensure it is draining correctly via the various Steam Traps and Drains


Boiler Operational ChecksBoiler Operational Checks

Boiler checks should be performed as per Company PolicyBoiler / Water Treatment / Compressor Daily ChecksA general inspection of the Boiler and Steam Supply Piping and Valving in the Plant is also recommended


Boiler ShutdownBoiler Shutdown

1. Ensure Burner is on low fire. If not, Shut Main Steam Stop Valve.

2. Switch Burner On/Off Switch to OFF3. The boiler will then shutdown.



4. Shut the Boiler Main and Bypass Gas Inlet Isolation Valves

5. Shut the Auto Blowdown Valve6. Check that water level is over 1/2 way in

steam drum, if not switch the FILL / OFF / AUTO switch to FILL, Feedwater Pumps will start.



7. When water level is ½ way (140), switch FILL / OFF / AUTO Switch to OFF

8. Shut Feedwater Isolation Valve.


Emergency ShutdownEmergency Shutdown

What is an Emergency Shutdown?– An Emergency Shutdown is required if:

There is a major system failure and the Boiler Automatics fail to trip the BoilerSome examples are:

– A large leak in the Feedwater System– A large leak in a Steam Line– Any Gas leak


Emergency ShutdownEmergency Shutdown

How is an Emergency Shutdown performed?

1. Switch the Burner On/Off Switch to OFF2. Shut the Boiler Main Gas Inlet Valve3. Shut the Boiler Main Steam Stop Valve4. Shut the Boiler Blowdown Valve5. Secure the area around the leak as required6. Log the event and monitor the Boiler


SummarySummaryLearning Outcomes– Understand NOHSC Boiler Classifications– Understand what are Attended, Non-Attended and

Limited Attended Boilers– Understand the differences between Attended, Non-

Attended and Limited Attended Boilers– Know who can operate Attended, Non-Attended and

Limited Attended Boilers– Describe the Control Philosophy differences between

Attended, Non-Attended and Limited Attended Boilers


SummarySummary

Learning Outcomes– List Dynamic Self Checking Devices Unattended

Boilers utilise– Define a Boiler– List the Principal Parts of a Boiler– List Boiler Mountings– Draw a single line drawing of the JH Boiler and

associated systems– Explain the purpose of the PLC and Control Systems


SummarySummary

Learning Outcomes– Explain what preparation is made for Start-Up– Explain how the Alarm System operates– Explain how to Silence Alarms and Reset the Boiler

after a trip– Describe the Start-Up Sequence– Describe the Operational Checks– Describe the Shutdown Sequence– Describe an Emergency Shutdown


SummarySummary

Application of Training– The best means of applying this training is to

perform Start-Up and Shutdown of the Boiler– DTW can provide a Training Log Book for

maintaining a copy of your On-the-Job Training

Training Session Feedback– At the end of this session please take the time

to provide your thoughts on the Training


Where to Get More InformationWhere to Get More Information

NOHSC– NOHSC 1006 (2001)

Australian Standards– AS 3873 Australian Standard for Pressure

Equipment Operation and Maintenance– AS 2593 Australian Standard for Unattended

Boilers

http://www.nohsc.gov.au/OHSInformation/NOHSCPublications/fulltext/docs/h3/4.htm



Workplace Health and Safety– Workplace Health and Safety Web Site– Workplace Health and Safety Act &

Regulations– Plant Advisory Standards– Certification System– Pressure Equipment Competency Units

Workplace Health and Safety– Workplace Health and Safety Web Site– Workplace Health and Safety Act &

Regulations– Plant Advisory Standards– Certification System– Pressure Equipment Competency Units

http://www.deir.qld.gov.au/workplace/index.htm

http://www.legislation.qld.gov.au/OQPChome.htm


http://www.deir.qld.gov.au/workplace/law/codes/plant/index.htm

http://www.dir.qld.gov.au/workplace/training/training/prescribed/what/index.htm

http://www.dtw.com.au/

http://www.deir.qld.gov.au/workplace/index.htm



http://www.deir.qld.gov.au/workplace/law/codes/plant/index.htm

http://www.dir.qld.gov.au/workplace/training/training/prescribed/what/index.htm

http://www.dtw.com.au/



Spirax Sarco Web Site– Learning Centre a useful resource for

Operators and EngineersDTW Designs (QLD) Pty Ltd– [email protected]– Phone 07-3300 2622 or 0438580374

Your Company Procedures

http://www.spiraxsarco.com/learn/

mailto:[email protected]

Documents

Basic & Intermediate Boilers Training Course