Basic & Intermediate Boiler Training Course - DTW Designs

Basic & Intermediate Boiler 

DTW Designs (QLD) Pty Ltd 

Training Course 

Owen Brischke 

DTW Designs (Qld) Pty Ltd 

RTO # 31507 

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15/09/2011

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. 


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Agenda 

The 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 


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Agenda (continued) 

Timetable 

– Expected duration is 8:00am to 4:00pm with 

breaks 

– Lunch approximately 12:00 noon 


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Topic One – NOHSC 

Classifications 

NOHSC is responsible for setting the guidelines 

for the safe operation of Pressure Equipment 

WHS Qld is responsible for managing 

registration and operator certification 

An example is defining Basic, Intermediate and 

Advanced Boilers and the Competencies required 

to operate them 

Would you expect NOHSC to define Unattended 

Boilers? 


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Topic Two – Registered Training 

Organisations (RTOs) Employers 

& 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 – Unattended and 

Limited Attendance Boilers 

Unattended and Limited Attendance 

Boilers have been designed for reduced 

Operator Attendance 

Are you aware of any sites with an 

Unattended Boiler? 


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Unattended 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 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 

AS2593 

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 

AS2593 

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 & 

Limited 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 & 

Limited 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 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 

Boiler 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 

Checking 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 – 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 Boiler 

Furnace – Energy Conversion 

Heating Surfaces – Absorption of Heat from the Furnace 

Steam/Water Separators – Separate Water from Steam 

Feedwater Supply – Provides the Water as the working 

medium for conversion to steam 

Draft Equipment – Fans for supplying air for combustion 

and removal of flue gas 

Fuel Supply – Provides the energy source 

Control Equipment – Controlling Start, Operation, 

Shutdown and Safe Tripping of Plant 


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Boiler Mountings 

Boiler 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 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 Boilers 


Fire Tube Boiler 

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Fire Tube Boiler Section 

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Water Tube Boiler Section 

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Water Tube Boiler Section 

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Water Tube Boiler Circulation 


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Enthalpy Curve 


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Feedwater 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 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 System 

A 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 


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Control 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 System 

A typical Feedwater Level Control System 


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Topic Five – Typical Maxitherm 

Boiler 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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Blowdown Valve 

Boiler Single Line Diagram 

Autoclaves 

Inlet Valve 

Blowdown to Waste 

Town Water Inlet 

Inlet Valve 

Steam to Autoclaves 

Brine Solution 

Brine Tank 

Outlet Valve 


To 

Waste 

Inlet Valve 

Drain Valve 

Vent to Atmos 

Heat Exchanger 

Treated Water 

To Feedwater Tank 

Water Softener 

Chem Pps 

Inlet Valve 

Steam to Dryers 

Boiler Steam 

Preheated Treated Water 

Feedwater Tank 

Inlet Valve 

Pipe Dryers 

Feedwater 

Tank 

No 2 Feed pump 

Condensate Return 

from Process 

Steam 

Trap 

Discharge to Boiler 

No 1 Feed Pump 

Discharge to Water Treatment 

Sparge 

FW CV 

FW Isol Vv FW Isol Vv 

Manual Bypass 

Vent to Atmos 

Blowdown Vessel 

Boiler Stop Valve 

Boiler Flue Gas 

To Atmos 

Boiler Flue gas 

Steam Drum 

Continuous 

Blowdown Valve 

Mud Drum 

Boiler 

Blowdown Line from Boiler 

Lvl 

Bleed Valve 

Block Valve 

FD Fan 

Gas Burner 

Gas Vent Line 

Gas Supply Line 

Block Valve 

Reducing Vv 

Isolation Valve 

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Gas Supply 

Main Pressure 

Reducer 

Pilot Pressure 

Reducer 


Flow 

Measurement 

Main Gas 


Pilot Gas 


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Gas Supply 


Bleed Valve 

Block Valves 

High Gas 

Pressure Switch 

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Burner Front 

Pilot Air Supply 

Igniter Transformer 


Flame Detectors 

Igniter 

Pilot Gas Supply 

Block Valves and 

Pressure Switches 

Pilot Gas Supply 

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Burner Front 

Low Gas 

Pressure Switch 


Air Supply 

Damper 

Fuel Gas and 

Air Supply 

Regulator 

Gas Regulator 

Valve 

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Softener and Chemicals 


Chemical 

Pumps 

Chemical 

Drums 

Water Softener 

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Feed Line to 

Feed Pumps 

Feed Pump Motors & Controls 

Feedwater 

Control Valve 

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Main Boiler 

Stop Valve 


Drum Level Control and 

Indication Probes 

Drum Vent 

Valve 

Pressure Gauge 

Drum Safety 

Valves 

Flue 

Gas 

Stack 

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Heat Exchanger 


Feedwater 

Preheater 

Flue Gas to Feedwater Preheater 

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Feed Pumps 


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Feedwater Control Valve 


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Maintenance Suppliers 

Chemical Supplies and Water Treatment 

– Drew Australia Pty Ltd 

Phone 3633 0277 

Boiler Maintenance 

– Tomlinson Boilers Pty Ltd 

Phone 3375 1360 


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Preparation for Start-Up 

Work Area Clean and Tidy 

All Lighting Serviceable 

Town Water Available 

Gas Supply Available 

Power Available 

PLC Available 

Operator Interface Available 


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Alarms 

Alarms are displayed on the Alarm Screen 

of the Operator Interface Computer 

Alarms should first be silenced, then read 

and acknowledged before rectifying the 

fault 

Once the fault is rectified the alarm should 

be cleared 


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Alarms 

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 Start-Up 

It is normal to check and set up the systems before 

firing. The following is a basic process. 

1. Open Feedwater Isolation Valve 

2. Open Boiler Gas Main and Bypass Inlet 

Isolation Valves 

3. Check Gauge Glasses are in service and water 

level is within limits 

4. Check the Boiler Pressure and if it is 

0 kPa then Open the Vent Valve on the Boiler 

Drum 


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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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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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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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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 


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Boiler Operational Checks 

Boiler checks should be performed as per 

Company Policy 

Boiler / Water Treatment / Compressor 

Daily Checks 

A general inspection of the Boiler and 

Steam Supply Piping and Valving in the 

Plant is also recommended 


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Boiler Shutdown 

1. Ensure Burner is on low fire. If not, Shut 

Main Steam Stop Valve. 

2. Switch Burner On/Off Switch to OFF 

3. The boiler will then shutdown. 


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4. Shut the Boiler Main and Bypass Gas 

Inlet Isolation Valves 

5. Shut the Auto Blowdown Valve 

6. 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. 


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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 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 Boiler 

Some examples are: 


– A large leak in the Feedwater System 

– A large leak in a Steam Line 

– Any Gas leak 

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Emergency Shutdown 

How is an Emergency Shutdown 

performed? 

1. Switch the Burner On/Off Switch to OFF 

2. Shut the Boiler Main Gas Inlet Valve 

3. Shut the Boiler Main Steam Stop Valve 

4. Shut the Boiler Blowdown Valve 

5. Secure the area around the leak as required 

6. Log the event and monitor the Boiler 


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Summary 

Learning 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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Summary 


– 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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Summary 


– 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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Summary 

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 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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Workplace Health and Safety 

– Workplace Health and Safety Web Site 

– Workplace Health and Safety Act 

– Plant Advisory Standards 

– Certification System 

– Pressure Equipment Assessment Instruments 


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Spirax Sarco Web Site 

– Learning Centre a useful resource for 

Operators and Engineers 


– admin@dtw-designs.com.au 

– Phone 07-3300 2622 or 0438580374 

Your Company Procedures 


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Basic & Intermediate Boiler Training Course - DTW Designs

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