Showing posts with label Boiler Boilerman 1. Show all posts
Showing posts with label Boiler Boilerman 1. Show all posts

Friday, 20 July 2012

Boiler Equipment House

13 Essential Fittings

1. Two (2) or I pair of Boiler Safety Valves
                Purpose:           First warning of high Steam Pressure
                Final warning of excessive pressure
                                         To protect the boiler from over pressure failure



2. Main Stream Stop Valve
                Purpose:          To isolate boiler from plant equipments.



3. Two (2) or One Pair of Water Level Gauge Glass
                Purpose:          To normally check water level
               To double check the water level
               Water sampling point (for middle level water sampling where applicable)

Tuesday, 17 July 2012

LAW AND REGULATION


Faderal Machinery Department Law:
a)      All pressure vessels must comply to the design requirement
·         F.M.D Act
o   BS 2790
o   ASME CODE
b)      All pressure vessel must comply to the required maintainance and inspection by F.M.D certified inspector
c)       All fire pressure vessels shall have a certified steam engine driver
·         Max tube plug – 5%

Questions:
  1. Why do you need a boilerman certified?
  2. Why annual inspection?
  3. How long before inspection is needed?

Responsibility Of Boilerman
a)      When accident in boiler house
·         Do whatever safety acts first, inform management and report to DOSH
·         Keep boiler log book record (if not, fine RM10000)

Make sure always read and understand the the regulation of Factory and Machinery Act. Read about Steam Boiler and Unfired Pressure vessel.
Note:
P.U.(A) 5/70 FACTORIES AND MACHINERY (STEAM BOILER AND UNFIRED PRESSURE VESSEL) REGULATIONS, 1970

LIST OF AMENDMENTS.

Amending law
Short title
In force from
P.U.(A) 172/70
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
21-5-1970
P.U.(A) 173/70
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
21-5-1970
P.U.(A) 174/70
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
21-5-1970
P.U.(A) 375/71
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) (Amendment) Regulations 1971.
21-10-1971
P.U.(B) 29/72
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
20-6-1972
P.U.(B) 112/77
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
10-3-1977
P.U.(A) 85/79
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
26-4-1979
P.U.(A) 86/79
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
26-4-1979
P.U.(A) 87/79
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
26-4-1979
P.U.(B) 655/80
Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.
11-12-1977


Monday, 9 July 2012

BOILER START UP, OPERATION AND SHUT DOWN

How to start a boiler?


Pre start up list
  1. Water check 
a)      Check softener proper functioning
b)      Check TDS of softener outlet water using the standard test kit
c)       Check water tank level
d)      Open the related water supply value, if needed
e)      Check chemical pump functioning and the chemical tank level to be fill up, if needed.
f)       Open the feed water pumps’ isolating value
g)      Check for any abnormal leakage along the water supply system.



Boiler Equipment House part 3

10. Two Feed Water Pump or 1 Pump Plus 1 Steam Injector Attachment (pressure 30% higher than boiler operating pressure)
                Purpose:              To pump water into boiler







11. Fusible plug
Purpose:              Mechanical way to prevent the boiler from overheating, when all the other safety features fail








12. P.M.D. Plate/Registration Plate
                Purpose:          To identified boiler registration with related authorities (JKKP, DOSH, etc..)
   




13. Manufacturer Name Plate
                Purpose:              Specification of the boiler




Common Question:
  1. Name the 13 Essential Fittings.
  2. How many necessary boiler fittings?
  3. Describe the functions of some of the essential fittings.

Sunday, 8 July 2012

Boiler Equipment House part 2


5. Inspector Pressure Gauge Attachment
                Purpose:              For double check of pressure gauge function by JKKP inspector





6. Blow down Valve
                Purpose:              For boiler water blow down so as to control the boiler water TDS.
                For boiler water level manual control so as to test the water level controllers











7. Feed water check valve
                Purpose:              One direction flow of fluid into the stream boiler
                Prevent back flow of steam into feed water tank





8. Low-Low Water Level Alarm
                Purpose:              To give warning on second low water level
i)                    Low-low water level alarm
ii)                   Low-low water level lock out










9. Low-Low Water Level Cut off (Burner Lock Out)
                Purpose:              To prevent boiler over heating failure










Tuesday, 3 July 2012

CHAPTER 1: INTRODUCTION TO BOILER


1. What is steam boiler?
Answer: Steam boiler is a steam generator producing steam at high pressure than atmosphere
 Figure 1.1 :  Steam Generator



2. What is temperature?
Answer: It is a measurement of heat energy level of hotness.
                 It is a measurement of Hotness / Heat Energy

Figure 1.2 : Temperature


3. What is pressure?
Answer: It is a measurement of force per units’ area.
Figure 1.3 :  Pressure Gauge

 

4. What types of boiler?


a) Electric Steam Boiler

Capacity:    15 kg/hr to 500 kg/hr

Pressure:        7 barg to 10 barg
                      7 kg/cm2 to 10 kg/cm2
                      100 psig to 145 psig
Manufacture:    Simon (Australia)
                       Fulton (USA)




Figure 1.4: Electric Steam Boiler






 


 
Capacity:    1000 PPH – 60000 PHH
Manufacture:    Mechmar Titan Boiler
                       IBAC Robey Boilers
        Maxitherm

 

Figure 1.5: Fire Tube Boiler

 

 

c) Water Tube Boiler – liquid fuel and solid fuel


                                                  Capacity:    200 kg/hr  – 60000 kg/hr

 
                                                 Manufacture:    Fraser I
                                                                         Fraser II (1993-1994)
                                                                         Bi Drum




 
Figure 1.6: Water Tube Boiler





5. What types of pass in Fire Tube Boiler?

a) Two (2) pass fire tube boiler.



Figure 1.7: Two Pass Reverse Flame Fire Tube Boiler

 
b) Three (3) Pass Fire Tube Boiler

Figure 1.8: Three Pass Fire Tube Boiler




 
6. What are other types of boiler?
a) Combine Boiler (Water Tube – Fire Tube Combination Boiler)

Figure 1.9: Combine Boiler



 

b) Water Tube Boiler (Bi-Drum)


Figure 1.10: Bi-Drum Water Tube Boiler

 

Figure 1.11: Principal of Bi-Drum Boiler

 
c) Tubeless Boiler



 

 

 

 

Figure 1.12: Tubeless Boiler