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3/11/2008DTW Designs (QLD) Pty Ltd1
Basic & Intermediate Boiler Basic & Intermediate Boiler Training CourseTraining Course
Owen BrischkeDTW Designs (Qld) Pty Ltd
RTO # 31507
3/11/2008DTW Designs (QLD) Pty Ltd2
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.
3/11/2008DTW Designs (QLD) Pty Ltd3
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
3/11/2008DTW Designs (QLD) Pty Ltd4
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?
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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.
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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?
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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.
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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.
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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
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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
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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
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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
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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.
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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.
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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.
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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.
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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
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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
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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
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Typical BoilersTypical Boilers
Fire Tube Boiler
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Typical BoilersTypical Boilers
Fire Tube Boiler Section
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Typical BoilersTypical Boilers
Water Tube Boiler Section
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Typical BoilersTypical Boilers
Water Tube Boiler Section
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Water Tube Boiler CirculationWater Tube Boiler Circulation
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Enthalpy CurveEnthalpy Curve
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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
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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
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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
3/11/2008DTW Designs (QLD) Pty Ltd29
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
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Control SystemControl SystemA typical Feedwater Level Control System
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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
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Boiler Single Line DiagramBoiler Single Line Diagram
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Gas SupplyGas Supply
Main Gas Isolation Valve
Pilot Gas Isolation Valve
Flow Measurement
Main Pressure Reducer
Pilot Pressure Reducer
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Gas SupplyGas Supply
Block Valves
Bleed Valve
High Gas Pressure Switch
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Burner FrontBurner Front
Pilot Gas Supply
Pilot Air Supply
Igniter Transformer
Pilot Gas Supply Block Valves and Pressure Switches
Igniter
Flame Detectors
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Burner FrontBurner Front
Fuel Gas and Air Supply Regulator Gas Regulator
Valve
Air Supply Damper
Low Gas Pressure Switch
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Softener and ChemicalsSoftener and Chemicals
Chemical Drums
Chemical Pumps
Water Softener
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BoilerBoiler
Feed Line to Feed Pumps
Feed Pump Motors & Controls
Feedwater Control Valve
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BoilerBoiler
Main Boiler Stop Valve
Drum Vent Valve
Drum Safety Valves
Drum Level Control and Indication Probes
Flue Gas Stack
Pressure Gauge
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Heat ExchangerHeat Exchanger
Feedwater Preheater
Flue Gas to Feedwater Preheater
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Feed PumpsFeed Pumps
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Feedwater Control ValveFeedwater Control Valve
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Maintenance SuppliersMaintenance Suppliers
Chemical Supplies and Water Treatment– Drew Australia Pty Ltd
Phone 3633 0277
Boiler Maintenance– Tomlinson Boilers Pty Ltd
Phone 3375 1360
3/11/2008DTW Designs (QLD) Pty Ltd44
Preparation for StartPreparation for Start--UpUp
Work Area Clean and TidyAll Lighting ServiceableTown Water AvailableGas Supply AvailablePower AvailablePLC AvailableOperator Interface Available
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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
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AlarmsAlarms
To Silence Alarms – Press MUTE on control panel.After an alarm condition has been rectified, press RESET to start Boiler if required.
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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
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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.
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Boiler StartBoiler Start--UpUp
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.
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Boiler StartBoiler Start--UpUp
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
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Boiler StartBoiler Start--UpUp
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
3/11/2008DTW Designs (QLD) Pty Ltd52
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
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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.
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Boiler ShutdownBoiler 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.
3/11/2008DTW Designs (QLD) Pty Ltd55
Boiler ShutdownBoiler Shutdown
7. When water level is ½ way (140), switch FILL / OFF / AUTO Switch to OFF
8. Shut Feedwater Isolation Valve.
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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
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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
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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
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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
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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
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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
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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
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Where to Get More InformationWhere to Get More Information
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
3/11/2008DTW Designs (QLD) Pty Ltd64
Where to Get More InformationWhere to Get More Information
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