steam

STEAM ENGINEER GRADE 1 AND 2 TRAINING

COURSE

Presented by;

Mohd Shafarudin Abdul Rasool

Steam / ICE Engineer Grade 1

Dip. Mech. Engg (UTM), B.Sc. in Mech. Eng. (UTM), M. Sc. B.E.M

(Warwick, U.K), Ph.D (UTM)

PART ONE - Introduction

What is our objective?

To facilitate the Engineers who wish to sit

for The Steam Engineers’ Competency Interview/Examination by The Department

of Occupational Safety and Health (DOSH)

Who is DOSH?

� A doctor?

� A lawyer?

� A teacher?

� A policeman?

� All of the above or non of the above?

Who is DOSH?

� Dept. under the Ministry of Human Resources

� Function – Make sure the occupational safety, health and welfare are taken care

� Vision – Peneraju Keselamatan dan KesihatanPekerja Terunggul

� Mission – Make sure Safety and Health of Worker is taken care

� Objective – Prevent Industrial Accidents and Occupational Illness

Enforcement Activities;

� Approval – Design, installation of m/c

� Registration – Plant, PMA, PMD, PMT

� Recognition – Competent Person & Firm

� Inspection – Initial, Regular, Supplementary, Special and Further for PMA, PMD, PMT

� Accident Investigation and Complaint

� Prosecution

What do they got to do with us?

� To check our health?

� To protect us if we’re

innocent or to punish if we’re guilty?

� To teach us the procedure?

� As an authority?

� As a busybody?

So, what……….?

� Since they are the authority and their job is to police us;

� So we need to know what are the rules, the Laws and Regulation…

� So than we don’t violate them!

What this has to do with Steam Certificate?

Well, similar with many other stuff….it is a mean to control.

Since to operate a boiler require certain skills and knowledge, thus the boiler operator need to be ascertained that they posses the prerequisite skills and knowledge.

These are what we are going to learn….

� About Act and Regulations…….

� Something about Boilers……..

� Some guidelines about Boiler Operations and Maintenance…….

� A bit about Boiler Water Quality……

Laws & Regulations- OVERVIEW

•Health and Safety Legislation, ‘94

•Factories and Machinery Act (Act

139) ‘67 – Currently OSHA

•Petroleum (Safety Measures)

Act.1984

�Perak Boiler Enactment 1903

�Machinery Ordinance 1953

�Factories and Machinery Act 1967

�Occupational Safety and Health Act 1994

History………..

The Act covers…..

• MACHINERY- Includes Steam Boiler , Unfired Pressure Vessels, Prime Movers, Gas Cylinders, Gas

Holders, Hoisting Machines, Transmission Machinery, and Driven Machinery .

• ALSO INCLUDED ARE ;- Any equipment for the casting and

welding of metals ,the spraying by compressed gas / air of metals / other

material.

The Act does not cover ….

• Machinery used for propulsion for vehicles

except for Steam Engine / Boilers

• Machinery driven by manual power , except

hoisting machines

• Machinery used solely for Private &

Domestic purposes.

• Office Machines .

Well , what have we learned so far ?

• Do we know who is DOSH ?

• Why do they exist ?

• What do we got to do with them ?

• What is Occupational Safety and Health

Art / Factories and Machinery Art ?

PART TWO – Laws & Regulation

FACTORIES AND

MACHINERY

(Boiler and Unfired

Pressure Vessel)

1970.

What we are going to learn ….

•Some Terminologies according to the act

•Under what circumstances do we need to

lias with DOSH ?

•Under what criteria do we need to have Steam Certificates?

Some terms to remember ….

•What is a Steam Boiler ?

•What is Authorized Safe Working Pressure (ASWP) ?

•What is Design Pressure ?•Who are Inspecting Authority?

STEAM BOILER …..

“STEAM BOILER” means any closed

vessel in which for any purpose steam is generated under pressure greater than the atmospheric pressure, and includes

any economiser used to heat water being feed to the boiler , and any superheater

used for heating steam , and any pipes and fittings connected there to .

Authorized Safe Working Pressure

means the maximum permissible pressure

at which a steam boiler or unfired pressure vessel may be operated as assigned by the

Chief Inspector and as stated on the current certificate of fitness relating to such steam boiler or unfired pressure vessel;

“Chief Inspector” and “Inspector” mean officers appointed under section 4 ( 1 ) of

the Act .

Design Pressure …

“Design Pressure” means the maximum

pressure at which the manufacturer of the steam boiler or unfired pressure vessel or any fittings or pipe work associated there

with designed to operate .

Inspecting Authority …..

“ Inspecting Authority ” means , in respect of any steam boiler or unfired pressure vessel

, an Inspecting Authority named in the Fourth Schedule to these regulations .

What is the job of the Inspecting Authority ?

• Review the design drawing prior to submission to DOSH .

• Carry out Quality Control inspection during

Manufacturing / Construction.

• Witness ( on behalf of DOSH – with permission ) any essential testing .

Dangerous Occurances

We also have to inform DOSH when there is;

• Explosion• Structure Failure• Loss of Boiler Water

• Boiler Tube burst• Fusible Plug burst

Critical Maintenance

We have to inform DOSH ;

• When the maintenance involves welding, patching or riveting

1.Must be done by qualified welder

2.Repair procedure submitted

3.This does not include normal maintenance work or tube replace of less than 10% (plug)

Periodical Inspection

For all certificated items( those with PMD’s, PMT’s as well as PMA’s) ;

• Every interval of 15 months

• Extension can be requested up to 36 months

BOILER Vs. CERTIFICATED STAFF

BOILER(S) HEATING

SURFACE OR OTHER

AGGREGATE HEATING

SURFACE

< 500 sq. ft.

If more than 1 boiler or

More than 1 steam

engine.

501 – 2,000 sq. ft.

2,001 – 5,000 sq. ft.

5,001 – 10,000 sq. ft.

If more than 1 boiler,or

More than 1 steam

engine.

CERTIFICATED PEOPLE REQUIRED

2nd grade or 1st grade driver, or 1st

/ 2nd driver to assist .

1st grade driver, other driver to assist

1st /2nd grade Visiting Engineer

• 1st grade driver

1st Grade / 2nd Grade Engineer 1st / 2nd grade driver to assist .

CERTIFICATED STAFF ( Cont. )

10,001 – 25,000 sq. ft.

If more than 1 boiler

25,001 – 50,000 sq.ft.

If more than 1 boiler; or

More than 1 steam engine

Comparison – A50 MWTNB boiler is approx. 400,000sq. ft.

1st grade Engineer

• Two 1st or 2nd grade Engineer to

assist.

• 1st or 2nd grade diver during each

shift.

1st grade Engineer

2nd grade Engineer to assist.

1st or 2nd grade driver to assist during

each shift.

Well , this is the end of part 2

I hope that you have learned the followings:-

• Some terminologies according to the art .

• About the Authorized Inspector.

• The role of DOSH

• WHY do we need steam Certificates.

Definasi

Definasi

� Boiler

� Act / Akta

� Regulation / Peraturan

� Rules / Kaedah

Boiler

� Mana-mana tangki tertutup yang digunakan untuk menjana stim padatekanan yang melebihi tekanan

atmosfera termasuk peralatan, superheater & economizer serta

kelengkapan lain yang ada terpasangpadanya

Act / Akta

� Undang – undang / Pekara – perkara‘Pokok’

� Dibincang dan diluluskan di Parliment

Regulation / Peraturan

� Perkara – perkara ‘Ranting’

� Dibincang dan diluluskan oleh Menteri

di Kementerian berkenaan

Rules /

� Hukuman / Penalty

� Undang – undang melibatkan

‘misconduct’

� Denda maksima RM 1000

� Perkara paling ditakuti oleh kilang –‘Seal’ kilang

Akta Kilang Dan Jentera

1967

(Act 139)

FMA 67 ada 15 Regulation, 4 Berkaitan Boiler

� FMA (Steam Boiler & UPV), Reg. 1970

� FMA (Person In-Charge), Reg. 1970

� FMA (Certificate of Competency-Examination), Reg. 1970

� FMA (Notification, Certificate of Fitness and Inspection), Reg. 1970

OSHA 1994 – Act 512

� OSH (Employers Safety & Health General Policy Statement) (Excep.) Reg. 1995

� OSH (Control of Industrial Major Accident Hazards) (CIMAH) Reg. 1996

� OSH (Safety & Health Committee) Reg. 1996

� OSH (Classification, Packaging & Labeling of Hazardous Chemical) Reg. 1997

� OSH (Safety & Health Officer) Reg. 1996

� OSH (Use & Standard of Exposure of Chemical Hazardous To Health) Reg. 2000

OSHA

1994

ACT 139

ARRANGEMENT OF SECTIONS

PART I - PRELIMINARY Section 1. Short title.

Section 2. Interpretation of "factory".

Section 3. Interpretation: general.

Section 4. Appointment of officers. Section 5. Supervision of officers.

Section 6. Officers are public servants.

Section 7. Powers of an Inspector.

Section 8. Obstruction an offence. Section 9. Persons not to reveal secrets.

PART II - SAFETY, HEALTH AND WELFARE

Section 10. Provisions relating to safety, etc.

Section 11. Persons exposed to explosive, inflammable, etc., substances. Section 12. Lifting of weights.

Section 13. Provisions against fire.

Section 14. Construction of machinery.

Section 15. Dangerous parts of machinery.

Section 16. Projecting material. Section 17. Machinery for hire or sale must comply with regulations.

Section 18. Machinery manufactured or repaired must comply with regulations.

Section 19. Certificate of fitness.

Section20.Dutiesofpersonsemployed.Section 21. Duties of occupier.

Section 22. Provisions relating to health.

Section 23. Exposure to elements.

Section 24. Personal protective clothing and appliances. Section 25. Provisions relating to welfare.

PART III - PERSON IN CHARGE AND CERTIFICATES OF COMPETENCY Section 26. Training and supervision of inexperienced workers. Section 27. Chief Inspector may make orders in circumstances. Section 28. Young persons. Section 29. Certain machinery not to be operated without certificated staff. Section 30. Panel of Examiners and Board of Appeal. PART IV - NOTIFICATION OF ACCIDENT, DANGEROUS OCCURENCE AND DANGEROUS DISEASES Section 31. Accidents and dangerous occurrence to be reported. Section 32. Notification of industrial diseases. Section 33. Investigation and enquiries. PART V - NOTICE OF OCCUPATION OF FACTORY, AND REGISTRATION AND USE OF MACHINERY Section 34. Operation of factory. Section 35. Building operations or works of engineering construction. Section 36. Installation of machinery, etc. Section 37. Application for registration. Section 38. Register. Section 39. Moving or alteration of or addition to machinery to be approved. Section 40. Periodical inspections. Section 41. Questions for decision by an Inspector and appeals from such decision. Section 42. Report of changes, etc. Section 43. Machinery or factory no longer in use. Section 44. Notice of sale, hire or transfer. Section 45. Copy of report of enquiry may be supplied. Section 46. Powers of the Chief Inspector and Senior Inspectors at enquiries. PART VI - GENERAL Section 47. Criminal or civil liability unaffected. Section 48. Fees. Section 49. Chief Inspector's powers. Section 50. Offences. Section 51. Penalties. Section 52. Prosecutions. Section 52A. Power to compound. Section 53. Power to modify agreements. Section 54. Power to apportion expenses. Section 55. Exemptions. Section 56. Regulations. Section 57. Medical supervision. Section 58. Repeal. Section 59. Amendment of Schedule.

FIRST SCHEDULE, SECOND SCHEDULE, THIRD SCHEDULEL, IST OF AMENDMENTS

ACT 139

REGULATIONS RELATED TO STEAM ENGINEER /ICE COMPETENCY/ RESPONSIBILITIES :

1. STEAM BOILER AND UNFIRED PRESSURE VESSEL2. ELECTRIC PASSENGER AND GOODS LIFT

3. FENCING OF MACHINERY AND SAFETY4. PERSONS IN CHARGE5. SAFETY, HEALTH AND WELFARE

6. ADMINISTRATION 7. CERTIFICATE OF COMPETENCY – EXAMINATIONS8. NOTIFICATION, CERTIFICATE OF FITNESS AND INSPECTION

9. COMPOUNDING OF OFFENCES10. COMPOUNDABLE OFFENCES11. LEAD

12. ASBESTOS PROCESS13. BUILDING OPERATIONS & WORKS OF ENGINEERING CONSTRUCTION SAFETY14. NOISE EXPOSURE15. MINERAL DUST

Apa OSHA 1994?

� Act Baru

� Occupational Safety & Health Act, 1994

� Tambahan kepada FMA 1967

� Mengawal dan melindungi kebajikan

dan keselamatan pekerja di kilang dantempat lain

OSHA 1994?

� Notification of Accident, Dangerous

Occurrences, Occupational Poisoning and Occupational Disease. (NADOPOD) – 7th

Regulation

� Record keeping (JKKP 8), Every 12 months to submit to DG by 31st Jan the following year.

� Record shall be kept at work place at least 5 years

� Penalty - < RM 10,000 of jail 1 year or both

OSHA 1994 – Act 514ARRANGEMENT OF SECTIONS

� PART I - PRELIMINARY

� PART II - APPOINTMENT OF OFFICERS

� PART III - NATIONAL COUNCIL FOR OCCUPATIONAL SAFETY AND HEALTH

� PART IV - GENERAL DUTIES OF EMPLOYERS AND SELF-EMPLOYED PERSONS

� PART V - GENERAL DUTIES OF DESIGNERS, MANUFACTURERS AND SUPPLIERS

� PART VI - GENERAL DUTIES OF EMPLOYEES

� PART VII - SAFETY AND HEALTH ORGANISATIONS

� PART VIII - NOTIFICATION OF ACCIDENTS, DANGEROUS OCCURRENCE, OCCUPATIONAL POISONING AND OCCUPATIONAL DISEASES, AND INQUIRY

� PART IX - PROHIBITION AGAINST USE OF PLANT OR SUBSTANCE

� PART X - INDUSTRY CODES OF PRACTICE

� PART XI - ENFORCEMENT AND INVESTIGATION

� PART XII - LIABILITY FOR OFFENCES

� PART XIII - APPEALS

� PART XIV - REGULATIONS

� PART XV - MISCELLANEOUS

� FIRST SCHEDULE. SECOND SCHEDULE. THIRD SCHEDULE

OSHA 1994?

Notification of Accident, Dangerous Occurrences

�To inform local DOSH office by phone / fax and report (Form JKKP 6) within 7 days

�Less serious – MC > 4 days , to include in JKKP 6

�Not serious no need to report

Occupational Poisoning and Occupational Disease. (NADOPOD) – 7th Regulation

�To inform local DOSH office by phone / fax and report (Form JKKP 7) within 7 days (Called by Employer or Employee)

�Must be diagnosed by a Registered Medical Practitioner

Mengapa perlu kepada OSHA 1994?

� FMA 1967, skopnya terhad

� FMA 1967 terlalu terperinci & banyak

spec

� FMA 1967 terlalu bergantung kepada

kerajaan

� Statistik kemalangan perusahaan

mungkin meningkat

OBJECTIVE OSHA 94

Mengapa perlu kepada OSHA 1994

� Memberi & melindungi keselamatan, kebajikan & kesihatan pekerja

� Melindungi orang luar kepada hazard ditempat kerja

� Mewujud suasana pekerjaan yang di perlukandari segi psychology & kehendak pekerja

� Mempunyai sistem keselamatan & kesihatanpekerjaan yang berasaskan undang2 & kodindustri yang praktik dimana ianyaberkombinasi dengan data

INDUSTRI YANG

TERLIBAT DGN OSHA

94

Industri yang terlibat

� Self Employee > 5 pekerja

� Construction > 20 M project

� Wood / Metal base > 100 pekerja

� Cement > 100 pekerja

� Petochemical > 100 pekerja

� Shipyard > 100 pekerja semasa peak

� Manufacturing / electronic > 500 pekerja

SAFETY HEALTH

OFFICER

Tugas;

� Pastikan OSHA 94 diikuti

� Promote Safety

� Assist & Nasihat dalam organizing OSH program

� Take part in inspection carried out by management

� Siasat kemalangan, penyakit, dangerous occurance & occupational disease

� Keep statistic on above

� S/u dalam Safety Committe

SAFETY HEALTH

COMMITTEE

� Wajib, industri > 40 pekerja

� Komposis jawatan mesti menyeluruh

� Majikan mesti consult SHC

� Committee;� Pengerusi - CEO / Top Mgt

� S/U - SHO

� AJK - Wakil pentadbiran

� Tugas AJK� Ikut sepertimana OSH

� Siasat & cari penyelesaian

� Perihatin pada laporan SHC

� Rujuk JKKP jika ada masalah

AKTA KILANG &

JENTERA 1967

( ACT 139)

FMA 67 ada 15 Regulation, 4 Berkaitan Boiler

� FMA (Steam Boiler & UPV), Reg. 1970

� FMA (Person In-Charge), Reg. 1970

� FMA (Certificate of Competency-Examination), Reg. 1970

� FMA (Notification, Certificate of Fitness and Inspection), Reg. 1970

FMA (SB & UPV) Regulation 1970

2. Interpretation

5. Manufacturing Boiler & PV

6. Import Boiler & PV

10. Essential Fittings

11. Fittings – General Provision

12. Safety Valves

13. Water Gauge

14. Pressure Gauge

15. Blowdown Valve

16. Main Stop Valve

17. Fusible Plug

18. Feed Check Valve

19. Low Water Fuel Cut Off

20. High Low Water Alarm

21. Inspector Test Attachment

22. Name Plate

41. Heating Surface

42. Steam Test

45. Corrosive Servicing Cond’n

72. Hydrostatic Test

73. Safety Valve Padlock

76. Opening Up Boiler / UPV

77. Maintenance

78. Notificable Occurrence

79. Repairs

87. Amendment Schedule

� 1st Sch – Material Code

� 2nd Sch– Design Code

� 4th Sch – Inspecting Authority

FMA 67 (SB & UPV) Reg. 2, INTERPRETATION

� ASWP

Authorized Safe Working Pressure

� Design Pressure

Tekanan Maksimum Dibenarkan

FMA 67 (SB & UPV) Reg. 5, MANUFACTURE BOILER & PV

� Mendapat kebenaran dari CI

� CI setuju, mendapatkan peralatan bersesuaian –adequately train - manufacturer

� Permohonan disertakan bersama (utk dapat ASWP)� 3 copy drawing – scale biggest

� All views, Principle dimension

� Material digunakan

� Scantling

� Joint type – welding, rivet

� Design Approval Fee

� CoF dikeluarkan bila diatas disertakan dan dapatASWP dari CI

FMA 67 (SB & UPV) Reg. 6 IMPORTED BOILER & PV

� Certificate / Data Report from Manufacturer (not for local boiler)

� Permohonan disertakan bersama (utk dapat ASWP)

� 3 copy drawing – scale biggest

� All views, Principle dimension, material spec, nozzle orientation, design temp & pressure, working pressure & temp, design

code, components & welding detail.

� Assembly drawing showing essential fittings

� Set of Formula & design pressure calculation

� Heating surface

� Scantling

� Design Approval Fee

� CoF dikeluarkan bila diatas disertakan dan dapatASWP dari CI

OSHA 1994 – Act 514Every steam boiler shall be provided with-

1. two or more safety valves,

at least one of which shall be of the direct spring-loaded type: h. s. 100 ft2 or less may have only one safety valve, in which case it shall be of the direct spring-loaded type;

2. two water gauges: evaporative capacity < 300 lb/hr may have only one water gauge

3. a steam pressure gauge;

4. a blown down valve or cock;

5. two feed pumps or alternatively one feed pump and one injector:

heating surface of < 150 ft2 or any boiler fitted with automatic controls which "fail to safety" may be fitted with one feed pump;

or two or more steam boilers are coupled together the number of pumps or injectors shall be approved by Chief Inspector;

6. a main steam stop valve;

7. a feed check valve;

8. an Inspector's test pressure gauge attachment;

9. a fusible plug in each furnace or combustion chamber: any boiler fired with liquid or gaseous fuel shall not have a fusible plug;

10. a low-water alarm; not required for any boiler which is fired with (a) solid fuel and generation steam at a pressure of 250 pounds per square inch or less; or (b) liquid or gaseous fuel and fitted with a low water fuel cut-out.

11. a low-water fuel cut-out where such steam boiler is fired with liquid or gaseous fuel;

12. the manufacturer's or maker's name plate; and

13. a registration plate.

FMA 67 (SB & UPV) Reg. 10, ESSENTIAL FITTINGS

� 4V� 2 u SV (1 mesti dari jenis Direct Spring Loaded)

� 1u SV bagi HS < 100ft sq – Direct Spring Loaded

� Main Stop Valve

� Blowdown Valve

� Feed Check Valve

� 5W� 2 u Feed Pump

� 1 U HS < 150 ft sq

� Fusible Plug

� 2 u Water Gauge� 1 U if eva < 300lb/hr alarm

� Low Water Fuel Cut Off and H&L Water Alarm

FMA 67 (SB & UPV) Reg. 10, ESSENTIAL FITTINGS

� 2G

� Pressure Gauge

� Inspector Test Attachment

� 2P

� Name Plate

� Registration Number

FMA 67 (SB & UPV) Reg. 11, FITTINGS-G’RAL PROVISION

� Tidak dibenarkan gunakan Cast Iron bagikelengkapan;� T > 400 oF, P > 100psi

� Peralatan & kelengkapan BD

� FV> 150 psi

� Tidak dibenarkan Tembaga/Gun metal untuk fittings operate T >435 oF

� All seat & Valve head mesti metal resistant corrosion

FMA 67 (SB & UPV) Reg. 12, SAFETY VALVES

� Peralatan wajib, adjustable – Buka pada ASWP;� Cukup Luas – Max blow bila P meningkat < 10% ASWP

� Max setting < 5% ASWP dengan kebenaran I

� Jika HS < 30 ft sq, dia oriffice > 3/4 in� Jika HS > 30 ft sq, dia oriffice > 1in� Keadaan asal tidak akan ganggu, free & full blow

� Ada spindle & lid boleh adjust� No stuffing box� SV jenis lever, pin/bush mesti non ferrous / corrosion metal resistant

FMA 67 (SB & UPV) Reg. 12, SAFETY VALVES

� Panjang – no load, L < 4in (o.d) coil, semasacompression, L >1/4 dia valve

� SV dipasang sedekat mungkin dengan shell & direct pada boiler shell – Tiada cock/valve

� Pasang bersudut tegak� Ada device untuk kunci adjusting screw� Boleh Lift-Off oleh easy gear (undar pressure)� Ada tanda manufacturer;

� Manufacturer’s name, dia. Orifice, design lift (in)

� Fungsi

� Mencegah tekanan didalam drum boiler meningkat ke suatu nilai yang telah ditentukan (allowable safe working pressure; ASWP) denganmelepaskan lebihan stim ke udara.

� Setiap boiler mesti dilengkapi dengandua atau lebih; satu dari jenis direct spring loaded.

� Bagi boiler yang mempunyai heating surface kurang dari atau pada 100 ka2,

boleh ada satu sahaja safety valve tapidari jenis direct spring loaded.

� Ada banyak jenis safety valves, antaranya;

� Spring loaded

� High Lift

� Dead weight

Safety Valve Setting/Floating

1. Inspector must be present

2. Fill up boiler with treated water

3. Pasang Inspector test pressure gauge padaInspector’s test pressure gauge attachment

4. Light off boiler

How?

5. Naikkan tekanan stim

6. Angkat lever bila tekanan mencapai 75% of the lowest-set safety valves

7. Naikkan lagi tekanan ke tekanan lowest-set s.v/v

8. Jika s.v. pops, kurangkan firing

9. Ambil bacaan tekanan pada bila s.v/v pops and reseats

Safety Valve Setting/Floating

10. Jika tak pop /reseat pada tekanan ditetapkan, kurangkan firing agar tekanan kurang danadjust the s.v/v’s spring compression and/or valve’s blowdown

11. Naikkan tekanan pada set pressure sekali lagidan ambil bacaan tekanan valve pops & reseats

12. Apabila s.v/v mula beroperasi, kurangkan firing kepada tekanan minima

13. Ulang langkah 10 - 12 sehingga tekanan yang dikehendaki diperolehi

Safety Valve Setting/Floating

14. Kurangkan tekanan stim pada suatu tekananyang selamat

15. Gag s.v/v yang baru disetkan

16. Naikkan tekanan stim kepada tekanan s.v/vyang kedua tinggi

17. Ulangi langkah 6 - 16 sehingga kesemuas.v/vs di setkan

18. Kurangkan tekanan stim pada tekananselamat dan buka kesemua gags

Safety Valve Setting/Floating

FMA 67 (SB & UPV) Reg. 13, WATER GAUGE

� Dipasang – Boiler Shell & Endplate /

Column

� Lowest visible, bawah LSWL

� Boleh dilihat dari firing position

� Ada cleaning plug

� Jenis tubular, ID >1/2 in, OD <3/4 in, protector. Disharge drain ada paip &

visible dari WG

FMA 67 (SB & UPV) Reg. 13, WATER GAUGE

� Self closing device pd bottom arm

� Cock;

� Sesuai & selamat bila WG pecah

� Normal position, S, W & D cock menegakdengan centre line

� Cleaning plug ada guard / gland

� WP > 100 psi, body insulated

� High Duty SB, can use WG jenis Globe Valve Type Down V

� Fungsi;

� Menunjukkan paras sebenar (sepatutnya)

air didalam stim drum. Maka dengan inioperasi atau pengendalian boiler dapatdilakukan dengan selamat.

� Setiap boiler mesti dilengkapi dengan

dua .

� Setiap boiler mesti dilengkapi dengandua .

� Bagi boiler yang beroperasi pada dankurang 300psi/h dan suhu pada 212 F, boleh ada satu sahaja gauge glass dengan syarat pada attachment gauge glass kedua mesti ada test cock.

� Ada banyak jenis gauge glass, antaranya;� Tubular � Plate � Reflex

Water Gauges Criteria

� To be fitted to the steam boiler end plate or shell

� If not practical, can be mounted on a column with minimum restriction to the ability to reflect the true water level

� Sound design and construction

� The lowest visible part higher than the lowest safe level

� Water level visible from firing floor (control room)

� Be fitted with cleaning plugs

Bagaimana test gauge glass?

� Pastikan kita memakai PPE – nyatakan

� Pastikan semua cock dalam kedudukan ‘service’

� Pastikan ada air dalam stim drum

� Pastikan tidak ada orang pada kawasan drain

� Berdiri disebelah g.g

� ‘Crack open’ drain cock selama 30 s kemudian baru full open –untuk elak glass pecah akibat ‘thermal shock’ – kita akannampak stim bercampur air keluar melalui drain

� Tutup water cock, kita akan nampak stim sahaja akan keluarmelalui drain

� Buka kembali water cock, dan ‘crack close’ selama 30 s dan full close steam cock, kita akan nampak air sahaja akan keluarmelalui drain

� Buka kembali steam cock dan tutup drain cock – pastikan air kembali keparas normal g.g

Bagaimana membersihkan gauge glass tersumbat?

� Pastikan kita memakai PPE – nyatakan

� Pastikan semua cock dalam kedudukan ‘service’� Pastikan tidak ada orang pada kawasan g.g

� Bawa spanner serta dawai sepanjang 3kaki yang depannya yang telahdibengkokkan

� Berdiri disebelah g.g. Pastikan bahagian air atau stim yang tersumbat. Kalaubahagian air tersumbat – dalam g.g tak nampak air dan kalau bahagian stimtersumbat – dalam g.g akan penuh air.

� Contohnya bahagian air tersumbat, maka dalam g.g tak kelihatan air� ‘Isolate’ kesemua valve pada bahagian air dan stim, tutup kesemua cock dan

buka drain cock, supaya air dan stim pada bahagian drain dapat dikeluarkan� Dengan menggunakan spanner, buka ‘cleaning plug’ pada bahagian air, dari

sebelah tepi g.g, gunakan dawai untuk mengorek serta bersihkan laluan / bukaan air pada g.g. Setelah pasti kesemua kekotoran telah dibersihkan, bukavalve air dan buka perlahan – lahan water cock serta buka habis supayakesemua kekotoran dapat diblow keluar.

� Pasang kembali ‘cleaning plug’ dan ‘inline’kan kesemua valve dan cock danpastikan air kembali ke paras normal g.g

� Jika masih tersumbat ulang semula procedur diatas

Bagaimana menukar kaca gauge glass yang pecah?

� Pastikan kita memakai PPE – nyatakan

� ‘Isolate’ kan stim serta water connection dengan menutup kedua-dua valve

� Tutup water dan stim cock dan buka drain cock

� Pastikan bawa spanner yang bersesuian. Buka nut g.g

� Buka dan tanggalkan kaca yang pecah

� Jangan guna kembali flat brass packing washers

� Pasangkan kaca baru yang tersedia ada, mesti 1/4” lebih agar dapat ‘play’ dan tahan ‘thermal expansion’

� Selitkan nut serta packing yang baru pada kaca baru

� ‘Centre’kan kaca serta ikat guna tangan dan akhir sekaliketatkan ¼ pusingan mengunakan spanner

� Setelah selesai, ‘on line’ kan kesemua valve serta crack open steam cock selama 10-20 min baru full open kedua dua cock dantutup drain cock

FMA 67 (SB & UPV) Reg. 14, PRESSURE GAUGE

� Di pasang highest, tegak. Dibaca dari firing

� Ada: siphone pipe, cock, handle selari bilaopen

� Dial;

� Dia > 6in min

� P (0), bacaan 1 1/3ASWP < P MAX < 2 ASWP

� Red mark pd ASWP

� Stop pin pada 0

� Accuracy Tolerence + 2% ASWP

� Fungsi;� Menunjukkan tekanan stim yang beradadidalam stim drum.

� Setiap boiler mesti dilengkapi dengansatu atau dua (auxiliary).

� Mesti disambungkan/pasang padabahagian tertinggi stim drum (steam site) dan dapat dilihat dengan jelas darijauh.

Pressure Gauge Criteria

� Connected to the position higher than the highest water level

� The dial in vertical plane

� Visible from firing floor (control room)

� Provided with siphon and an isolating cock/valve

� Have dial > 6” dia

� Range from zero to;

� Not less than 1 1/3 ASWP

� Not more than 2X ASWP

� Have RED mark at ASWP

� Have a stop pin at Zero pressure

� Tolerance 2% of ASWP

FMA 67 (SB & UPV) Reg. 15, BLOWDOWN VALVE

� Dia bore > 1in - Di pasang supaya mudahbuka & tutup BDV

� BD cock bolted dengan cover / double gland

� SB jenis shell;

� Dipasang terus pada shell dibhg terdekat & terendah pada steam drum

� Pipe;

� Mempunyai 2 / lebih S pipe & dipasang main pipe

� Valve jenis screw down non-return

� Fungsi;

� Mengawal kualiti air yang berada didalam

drum(bahan kimia) – TDS.

� Mengosongkan drum untuk tujuan

mencuci, memeriksa dan pembaikkanboiler.

� Mengawal ketinggian air dalam drum.

� Membuang sludge dan sediment

(kotoran)

� Setiap boiler mesti dilengkapi dengansatu atau dua (auxiliary).

� Mesti disambungkan/pasang padabahagian paling bawah drum (water side).

� Pada kebiasaan pada sambunganblowdown terdapat / terdiri dari duavalves; satu jenis cepat buka dan satulagi jenis stop valves (screw).

� Valve cepat buka (jenis lever operated gate valve) mesti berada sedekatmungkin dengan kelumpang(shell)

boiler.

� Semasa blowdown, quick opening

valve mesti dibuka dahulu dan paling akhir ditutup semula.

Bagaimana membuat blowdown?

� Pastikan kita memakai PPE – nyatakan Pastikan semua b/down valve dalam kedudukan ‘service’

� Pastikan tidak ada orang pada kawasan b/down pit / chamber

� Pastikan ada air pada paras normal sebelum b/down dibuat

� Jika dari kedudukan b/down, kita tidak dapat melihat g.g, kitastationkan seorang pembantu di tempat g.g

� ‘Crack open’ dan full open fast open valve

� Buka slow open valve – pastikan kita dapat melihat paras air dig.g

� Setelah puas hati kuantiti air yang hendak dibuang, tutup slow open valve

� Tutup fast open valve dan buka kembali slow open dan tutupkembali slow open

� Pastikan air kembali ke paras normal g.g

� Fungsi;

� Mengepam air masuk kedalam drum.

� Setiap boiler mesti dilengkapi dengan dua pam. Atausatu pam feed dan satu lagi injector. Mana-manaboiler yang mempunyai heating surface pada ataukurang 150 ka per boleh mempunyai satu feed pump dengan syarat mempunyai kawalan automatic yang ‘fail to safety’.

� Bagi dua atau lebih boiler yang dipasang bersiri makajumlah feed pump dari jenis apa mestilah mendapatkelulusan JKKP.

Feed Pump FMA 67 (SB & UPV) Reg. 16, MAIN STOP VALVE (MSV)

� Di pasang direct pd shell boiler. Jika adas/heater – atas header

� Tinggi pipe & flanges < 5x dia MSV

� Jika common Steam pipe;� NRV guna Self Closing Type

� V mesti interposition dengan MSV

� Marked pada valve;� Manufacturer Name

� Design Pressure

� Indicate – Flow Direction & Closing of the h. wheel

� Fungsi;

� Membenarkan aliran stim dari stim drum

ke header.

� Berhentikan /isolate aliran stim ke

header.

� Valve ini adalah jenis outside stem and yoke gate valve. Perjalanan stimadalah lurus (terbuka terus atau

tertutup terus)) dan menghalangaliran stim menukar arah (direction).

� Jenis valve ini akan memberigambaran jika valve tersebut terbuka

atau tertutup hanya dengan melihatstem valve tersebut.

FMA 67 (SB & UPV) Reg. 17, FUSIBLE PLUG

� Highest mungkin pada LWL

� Early Protection

� Body dibuat dari Tembaga / Gun Metal� Bhg tengah bentuk cone dia <3/8 in

� P < 100 psi, plug dia ½ in

� Annular Lining;� Full drop & clear bila melting

� Melting Temp., T< 150 deg F + T saturated

� Fungsi;� Merupakan penunjuk terakhir berlakunya

paras air rendah sebelum tiub mulaterbakar. Amaran dalam bentuk bunyi.

� Hanya terdapat pada boiler yang menggunakan bahan api jenis soildfuel.

� Diperbuat dari tembaga yang mempunyai tread halus diluar dansatu lubang tapper yang diisi timah. Timah ini akan cair apabila plug tidaklagi dikelilingi oleh air (semasakekurangan air) dan suhu dalam shell melebihi 450 deg F.

� Terdapat dua jenis;

� Fire side

Ia disekrukan dari fire side ke water side.

� Water side

Ia disekrukan dari water site ke fire side.

� Biasanya dipasang 2.5 - 3” pada tiub paling tinggi.

� Ia mesti ditukar setiap kali melakukan annual shutdown atau sekurang kurangnya setahunsekali.

FMA 67 (SB & UPV) Reg. 18, FEED CHECK VALVE (FCV)

� Di pasang direct pada shell

� Jenis screw down non-return / NRV + Regulating Screw Down

� Feed pipe dari FCV mesti diatas LWL & bhgjoint;� Permukaan terbuka tidak kepada direct radiation (shell tanpa isolation)

� Boleh operate dari firing position

� 1 cukup. Although terdapat >2 water source

� If ada > 2 SB dipasang common water pipe , iso v/v mesti dipasang pd branch setiap SB iaitu diantara FCV & FP

FMA 67 (SB & UPV) Reg. 18, FEED CHECK VALVE (FCV)

� If FP type Reciprocate , RV dipasangantara FCV &FP

� FRV / comb. Regulating + NRV mestiada marking water flow direc. & hand wheel

� NRV mesti ada water flow direc.

� FCV mesti ada;� Manufacturer/Marker’s Name

� DP

� Fungsi;

� Mengawal aliran air yang memasuki

kedalam drum boiler pada satu arahsahaja dan menghalang air dari terkeluardari stim drum ke feedwater line.

� Setiap boiler mesti dilengkapi dengan

satu

FMA 67 (SB & UPV) Reg. 19, LOW WATER FUEL CUT-OFF

� Dipasang pada burner control system

� Internal part dibuat dari non-corrosive metal

� Design;

� Mudah BD

� Cuci

� Pemeriksaan dan test

� Fungsi;� Memadamkan/mematikan burner semasa

berlaku paras air rendah.

� Burner hanya boleh dihidupkan secaramanual

� Perlu pada boiler yang mengunakanliquid/gas fuel

� Terdapat 3 jenis;� Float Magnet

� Float Linkage

� Electrode probe

FMA 67 (SB & UPV) Reg. 20, HIGH-LOW WATER ALARM

� Dipasang pada burner control system

� Internal part dibuat dari non-corrosive metal

� Design;

� Mudah BD

� Cuci

� Pemeriksaan dan test

10. Low Water Alarm

� Fungsi;

� Memberi amaran (loceng/pengera) semasaberlakunya air tinggi atau rendah dalam drum.

� Dapat dilaraskan selepas dipasang serta akanberbunyi apabila paras low – paras air masih

boleh dilihat semasa loceng bebunyi

� Tidak perlu kepada boiler yang menggunakansolid fuel dan menjana stim pada dan dibawah250 psi. Serta pada boiler yang menggunakanliquid/gas fuel yang mempunyai low water fuel cut-out.

FMA 67 (SB & UPV) Reg. 21, INSP’TR TEST ATTACHMENT

� V yang sesuai, vertical & socket

mempunyai removable plug/cap

� Highest near PG

� Fungsi;

� Menguji ketepatan tekanan semasa

setting ASWP atau HT.

� Kebiasaan inspector akan

mengunakan pressure gauge yang telah diuji ketepatannya. Dan akandigunakan bersama-sama pressure

gauge yang tersedia ada.

FMA 67 (SB & UPV) Reg. 22, NAME PLATE

� Permanent marking;

� Manufacturer/maker’s

� name & address

� Serial no.

� DP

� CODE/Spec/Rule of Design Boiler

� HT Pressure & date

� Fungsi;� Bagi mengetahui asal-usul boiler,

datangnya dari mana.

� Perlu ada tercatit;� Nama dan alamat pembuat

� Nombor siri pembuat

� Design pressure

� Kod, spesifikasi serta rule bagimanaboiler tersebut direkabentukan

� Tekanan HT

� Tarikh dilakukan HT

No pendaftaran boiler ( PMD….)

PMD1234

FMA 67 (SB & UPV) Reg. 41, HEATING SURFACE

� Determine SV area & Inspection Fee

� Total h.s every plate, tube drum exposed to flue gas & contact with water on the other side

� Measurement according fire/water side which is greater

� Usually;� WTB – external

� FTB – internal

FMA 67 (SB & UPV) Reg. 45, CORROSIVE SERVICING CONDITION

� UPV yang terlibat dengan keadaan corrosive, abrasive/erosive

� Total h.s every plate, tube drum exposed to flue gas & contact with water on the other side

� Measurement according fire/water side which is greater

� Usually;� WTB – external

� FTB – internal

FMA 67 (SB & UPV) Reg. 73, SAFETY VALVE PADLOCK

� SV sudah set mesti di lock

� Lock serah pada PIC

FMA 67 (SB & UPV) Reg. 76, OPENING-UP SB / UPV

� Tak boleh buka for repair, cleaning / apa2 kerja kecuali P=0 dan sejok

� Free from hazardous fumes & vapour

� Disconnect/blank hot water & steam line section

� Maksud disconnect/blank

� Removal of MSV, FCV, BDV

� Removal piping antara SB/S receiver from pressure source

� Blank MSV & pressure source

� Padlock > 2 STOP V antara SB & source of P

FMA 67 (SB & UPV) Reg. 77, MAINTENANCE

� Owner/Engineer/Occupier/Dragmaster

mestilah

� SV, WG, PG dan all fitting mesti maintain

� Fusible metal bagi setiap FP renew setiap 2

years

FMA 67 (SB & UPV) Reg. 78, NOTIFICABLE OCCURANCE

� Effect on boiler strength

� Report to JKKP secara verbal & written

� Perkara/kejadian perlu report

� Air kering

� Fusible Plug metal cair

� Tube Burst

� SB structure fail

� Explosion

� Kemalangan melibatkan nyawa

DANGEROUS OCCURANCES1. Boiler & UPV;• Explosion or Structure Failure

• Loss of Boiler Water• Boiler Tube burst

• Fusible Plug burst

2. Bursting of revolving vessel, wheel grinding wheel etc

3. Collapse or failure of hoisting m/c.4. Explosion or fire or failure of structure affecting the safety of any room or place

of work.

FMA 67 (SB & UPV) Reg. 79, REPAIRS

� Hantar procedure repair, spec & JKKP approval

� Jenis repair;� Cutting

� Patching

� Welding

� Riverting

� Welding- MAW tak boleh ada gas

� C.I parts tak boleh weld

� Selepas repair kena dapat JKKP approval

� Tak termasuk normal maint. work jika boiler ditukar< 10% total tube

� Hanya qualified welder

FMA 67 (SB & UPV) Reg. 87 AMENDMENT SCHEDULE

� 1st Schedule - Material Code� BS 1501

� Steel for Fired and Unfired PV

� 2nd Schedule – Design Code� BS 1113

� WTB & their integral SH

� BS 2790� Cylindrical land SB of welded construction (other than WTB)

� 4th Schedule – Inspecting Authority� Lloyds Register of Shipping, Paris

� Bureau Veritas Int. Register of Shipping, Paris

� Nat & Vulcon Eng. Ins. Group, Manchester

What is the job of the Inspecting

Authority ?

• Review the design drawing prior to submission to DOSH .

• Carry out Quality Control inspection during Manufacturing / Construction.

• Witness ( on behalf of DOSH – with permission ) any essential testing .

If you’re to ….. Boiler ,

MANUFACTURE CONSTRUCT

OPERATE

DOSH

To Manufacture a boiler …..

LICENCE TO

MANUFACTURE

DESIGN

APPROVAL

QUALITY

CONTROLFINAL TESTING

DOSH

To construct a boiler ……

LICENCED

CONSTRUCTOR

DESIGN

APPROVAL

QUALITY

CONTROL

FINAL

TESTING

DOSH

To operate a boiler ……

CERTIFICATED

OPERATORPERIODICAL

INSPECTION

CRITICAL

MAINTENANCEDANGEROUS

OCCURANCE

DOSH

FMA 67 (SB & UPV) Reg. 4 -Sec 56(1) PERSON INCHARGE

H.S. (ft sq) Person In-Charge

HS <500 2nd ED/shift

500<HS<2000 1st ED/shift

2000<HS<5000 1st ED + 2nd/1st VE

5000<HS<10000 2nd SE/1st SE

10000<HS<25000 1st SE + (Asst 2nd /1st SE, if >1 SB

25000<HS<50000 1st SE + (Asst 2 ORG 2nd /1st SE, if >1 SB

> 50000 1st SE + 2nd /1st SE / shift

Borang

JKKP

Borang JKKP;

� JKJ 105

� Layout

� Permohonan pemasangan peralatan di permis

� JKJ 14

� Perakuan Kelayakan (CF)

� JKJ 127

� HT Certificate – untuk dapat sijil pendaf. PMT

Tugas Visiting Engineer

Tugas;

� Lawatan Kilang 2x sebulan

� Sedia & Submit report sebelum 10hb ke JKKP

� Terlibat sebarang inspection oleh JKKP

Jenis Inspection

Keperluan Inspection;

� Initial Insp.� Plant & m/c baru

� Regular/Annual Insp.� 12 / 15 bulan

� Supplementary Insp.� Spot check – no notice

� Special Insp.� HT, Accident, Commissioning

� Further Insp.� Come with notice to verify m/c listed operating

Boiler

Tubes - Type

Name of Tubes;

� Generating Tube

� Kedudukan direct kepada flue gas

� Material – Medium Carbon Steel

� OD – 50 to 76mm & Thick – 3.2 to 4.5mm

� Downcomer Tube

� Not direct to flue gas

� D > 150mm (6in)

� Superheater tube

� Material – High Carbon Steel

� To generated superheated steam

Name of Tubes;

� Distributing Tube / Injector

� In upper drum, from FCV to inner sec. Below LWL

� There’s hole 1/8 in facing down to avoid kocakkan(cavitations) air

� To distribute water in drum

� Economizer Tube

� To increase FW temp.

� To lower flue gas temp escaping to exhaust

� Last pass