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UNDERSTANDING

STEAM BOILERS

LEGAL REQUIREMENTSOF STEAM BOILERS

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UNDERSTANDING STEAM BOILERS NIOSH 2007

SCOPE

By the end of this session the participants willbe able to understand all the legalrequirements with regard to steam boilers,including :

HISTORY

DESIGN APPROVALS

INSTALLATION AND CERTIFICATION

PERSONS IN CHARGE

STATUTORY INSPECTIONS, AND

PENALTIES AND FEES

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HISTORY OF OSH IN MALAYSIA :

FIRST INDUSTRY IN MALAYA

Tin has been known from ancient times. Ancient peoples found thatby heating the tin mineral cassiterite (sometimes found in streamsas nuggets) in a charcoal fire, they could produce the silvery, softmetal we know as tin.

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HISTORY OF TIN MINING

The earliest use of machinery came with thediscovery of a major tin field in Larut, Perak in

1848, and in Kinta in 1880.

Sir Hugh Low introduced the steam engines andcentrifugal pumps in Taiping in 1877.

When the railway track between Larut, Port Weldand Taiping was completed in 1885, alluvial tinmining using the water-wheel driven chain pumpwas replaced by open cast mining usingpowerful water jets driven by centrifugal pumps.

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The First Steam Engine

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THE STEAM ENGINE

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With the boilers came the Boiler Inspectors.

1878 : FIRST BOILER INSPECTOR IN PERAK,appointed by the Perak Mines Department.

There were 120 boilers recorded in Perak in 1892.

1896 : SELANGOR BOILER ENACTMENT, SELANGOR

1913 : MACHINERY ENACTMENT FOR DRIVENMACHINERY, (FEDERATED MALAY STATES)

1924 : PENANG BOILER ENACTMENT

1937 : JOHOR BOILER ENACTMENT

HISTORY of FMA & OSHA

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At the same time, steam boilers were

also used in the Palm Oil Mills

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1932 : MACHINERY ENACTMENT (AMENDMENT)

NEW REQUIREMENT : QUALIFYING EXAMSFOR STEAM ENGINEERS AND DREDGEMASTERS

1951 : Mining machinery formed only 20% of total

work load

1953 : THE MACHINERY ORDINANCE

THE BOILER INSPECTORATE SEPARATEDFROM THE MINES DEPARTMENT

BECAME THE MACHINERY DEPARTMENT,

UNDER THE MINISTRY OF LABOUR


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1967 : THE FACTORIES AND MACHINERY ACT(MODELLED AFTER THE FACTORIES ACT, UK)

15 REGULATIONS UNDER FMA,

INCLUDING THE FACTORIES AND MACHINERY

(STEAM BOILER AND UPV) REGULATIONS,1970

1980 : FMA EXTENDED TO SABAH AND SARAWAK

1980s : REGULATIONS ON HEALTH :

LEAD, NOISE, ASBESTOS AND MINERAL DUST


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OBJECTS OF FACTORIESAND MACHINERY ACT, 1967

TO PROVIDE FOR THE CONTROL OF FACTORIES

WITH RESPECT TO MATTERS RELATING TO :

1. SAFETY, HEALTH AND WELFARE OF

PERSONS, AND

2. REGISTRATION AND INSPECTION OFFACTORIES AND MACHINERY

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With New Industries, come

New Safety And Health Problems Agriculture based Manufacturing based

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LIMITATIONS OF THE FMA 67

1. FMA ONLY COVERS FACTORIES, QUARRIES

AND BUILDING CONSTRUCTION SITES

2. THE REQUIREMENTS WERE PRESCRIPTIVE

3. OSH NOT COVERED BY OTHER DEPARTMENTS

OCCUPATIONAL SAFETY AND HEALTH ACTS

1970 : OSHA US1974 : HASAWA, UK

1985 : OHSA, AUSTRALIA

1994 : OSHA, MALAYSIA


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Objects of the OSH Act, 1994

To secure the safety, health & welfare of persons atwork

to protect persons (other than persons at work)

against hazards at a place of work, to promote the occupational environment adaptable

to the persons physiological & psychological needs

to provide the means towards a legislative systembased on regulations and industry code of practice

in combination with the provisions of the Act

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S 15(2) Responsibilities of Employers

The provision & maintenance ofa) safe plant & system of work

b) safe use, handling, storage, transport of

materialc) information, instruction, training &

supervision

d) safe workplace, access & egress

e) safe working environment

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DESIGN APPROVALS

Steam Boiler : closed vessel in which

steam is generated under pressure greater

than atmospheric pressure, and includes

economizer and superheater.

Section 18 FMA :

1) No person shall manufacture, repair or installmachinery in such a manner that it does not

comply with the provisions of this Act and

regulations

2) No person shall import any machinery other than

transmission machinery which does not comply

with any regulations made under this Act.

Note : Machinery includes steam boilers.

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DESIGN APPROVALS

Manufacturer Design : Max Allowable Working Pressure

DG of DOSH assigns the Authorized Safe Working

Pressure. (Reg 7 & 8, Steam Boiler and UPV Regulations

1970.)

Submit documents to the Design Section of DOSH HQ in

Putrajaya :

Design calculations to an approved code in the 2ndSchedule, e.g. BS 1113 (W/T), BS 2790 (F/T), ASME

Section 1, and TRD.

3 copies of detailed construction drawings, withprincipal dimensions, details of materials, welding

joints and all data necessary to assign an authorised

safe working pressure.

Other details : heating surface, MCR

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DESIGN APPROVALS

Submit documents to the Design Section at DOSH

headquarters in Putrajaya : cont.

an Approved Third Party Inspecting Authority Report :5th Schedule;

List of Inspecting Authorit ies include : Lloyds Register

of Shipping, London; Bureau Veritas, Paris; HartfordSteam Boiler Inspection and Insurance Co, USA; TUV,

Germany; SGS, DNV, ABS, and recently, SIRIM QAS.

Manufacturing Data Report (MDR) from the

manufacturer of the steam boiler describing particularsof material used, design, pressure, design code, serial

number and hydrostatic test reports, to be submitted

to DOSH officer during the fisrt inspection or

hydrostatic test.

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LOCAL MANUFACTURERS

Have to prove to DOSH that they have theability to produce steam boilers in terms of :

Manufacturing facil ities, Qualified technical staff who can design and

fabricate boilers according to accepted

design codes, Quality Assurance Program, and

Welders certified by DOSH.

During fabrication : supervised and surveyedby an approved third party InspectingAuthority.

Repairers : comply with similar conditions

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FABRICATION : FIRE TUBE

Allen Ygnis

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INSTALLATION AND CERTIFICATION

No person shall buy, install, repair, modify orsell any boiler without approval of DOSH.(Section 17, FMA 1967).

No person shall operate a boiler without avalid certificate of fitness (Section 19, FMA 1967)and boiler attendant and steam engineerasrequired. (Section 29, FMA 1967).

All boilers have to be opened up forinspection before the certificate of fitness canbe renewed. (Regn 10&14, Notification, Certif icate of

Fitness and Inspection Regn, 1970) Boilers can only be repaired by approved

Boiler Repaircompanies after the repair

procedure has been approved by DOSH.

13 ESSENTIAL FITTINGS

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2 or more safety valves

2 water gauges

A steam pressure gauge

Main steam stop valve

A blow down valve 2 feed pumps, same output pressure

Feed check valve

A low water alarm

A low water fuel cut-out

(liquid and gaseous fuel)

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SAFETYVALVESSAFETYVALVES

MAIN STEAM

STOP VALVE

MAIN STEAM

STOP VALVE

AIR COCKAIR COCKPRESSURE GAUGEPRESSURE GAUGE

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PRESSURE GAUGEPRESSURE GAUGE

What is thepressure in

bars?

What is thepressure in

bars?

WATER LEVEL GAUGESWATER LEVEL GAUGES

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WATER LEVEL GAUGESWATER LEVEL GAUGES

WATER

COCK

WATER

COCK

DRAINCOCKDRAINCOCK

STEAM

COCK

STEAM

COCK

GAUGE

GLASS

GAUGE

GLASS

Which

valvesareopen?

Which

valvesareopen?

AA BB

B Bl D V l

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Burner, Blow Down Valve

Burner

Blow-down valve

FEED WATER PUMPS

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FEED WATER PUMPS

ElectricalElectrical Steam-

turbine

Steam-turbine

MANHOLE

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MANHOLE

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Manufacturers name plate Manufacturers Serial Number

Model No.

Output (MCR) Design pressure

Hydrostatic test pressure

Date of the hydrostatic test Third Party Surveyor

Design code

Manufacturers name andaddress

(Heating surface, Maximumevaporative capacity)

(DOSH design approval)

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A registration plate

Inspectors test pressure gauge attachment

A fusible plug in each furnace(solid fuel only)

??


PMD 23456PMD 23456PMD 23456PMD 23456

SW PMD 234SW PMD 234SW PMD 234SW PMD 234

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FUSIBLE PLUG

2

Stay bar Fusible plug

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INSTALLATION & TESTING

Application to local DOSH office forpermission to install any steam boiler.

Form JKJ 105 Layout plan, and

Copy of the design approval.

The first test : hydrostatic testing to 1.5times design pressure (Form JKJ 127)

The second test : steam or fire test.

Setting of the safety relief valves,

Testing of the high and low water alarmsand blowdown.

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CERTIFICATE OF FITNESS

Certificate of Fitness : issued after paymentof the HT and inspection fees. Fees arebased on heating surface area.

Certificates valid for 15 months, and the localDirector may grant an extension of 3 months.

Extension of validity to 36 months only by

the Chief Inspector. Justification : Reasons why it cannot be opened for

inspection,

Proof that it can operate safely for 36 months.

Application must be made through the localDOSH office, 6 months in advance.

TBI RBI SSI (FMA Amendment, 2006)

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PERSONS IN CHARGE

Certificate issued by the Department under the Factories

and Machinery (Persons-In-Charge) Regulations 1970.

Steam Engineers and Engine Drivers are examined by a

panel of examiners on the operational safety of the plant.

< 500 sq ft : 2nd grade Engine Driver

500 2,000 sq ft : 1st grade ED

2K 5K sq ft : 1st grade ED + 2nd Grade VE

5K 10K sq ft : 2nd grade Engineer + 1st grade ED.

> 10K sq ft : 1st Grade Engineer + +

2 boilers or 2 steam engines or 1 boiler and 1 engine to

each driver. Boilers on standby not counted.

Note : Based on aggregate heating surface of steam boilers

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ENGINE DRIVER CERTIFICATE

39/60 GRADE ONE

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GRADE ONE

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PERSONS IN CHARGE

EXEMPTIONS :

An electrode boiler A steam tube oven

A steam tube hot plate

An autoclave

Any steam boiler in which the steam

generated is retained inside the boilere.g. a steam jacketed vessel.

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CERTIFICATES OF COMPETENCY

Steam Engineer :

Not less than 21 years of age

Degree or diploma in Mechanical

Engineering

Completed qualifying workshopservice: metal turning, boiler making,

design and drawing

Has served not less than 24 monthsunder an engineer in operational

charge of boiler of the required size


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Exam for Engineers :

Part A : Practical Mathematics

Part B : Engineering Knowledge Part C : Oral

Exemption from Part A & B :

Holder of a recognized degree inMechanical Engineering is exempted from

Parts A & B. Others may be eligible for

exemption, at the discretion of the panel. Knowledge on safe operation of steam boiler

and allied equipment.


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43 UNDERSTANDING STEAM BOILERS NIOSH 2007


Engine Driver 2nd Grade:

Not less than 21 years of age

Has served not less than 2 years as asteam boiler attendant in charge of a

boiler which requires an attendant; or

Has served not less than 3 years as anapprentice or journeyman fitter in a

steam plant or engineering workshop

Engine Driver 1st Grade: Not less than 18 months as a 2nd grade

engine driver, working with a boiler

with a heating surface > 500 sq. ft.


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Suspension of Certificate

Sleeping while on duty

Intoxicated while on duty Leaving machinery unattended

Failure to report any defect which may

cause danger to life or property, or Causing damage to machinery or

injury to any person by

Careless operation of machinery or Neglect of routine instructions, or

Neglect of use of safety appliances

provided

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Fireman : Is he a boilerman?

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u es o s g g ee

The visiting steam engineer :

Visits the boiler once every 2 weeks and

Maintains a boiler register. The boiler registerentrees must be countersigned by the owneror occupier.

The register entrees are as follows :

Report on current condition of boiler Details of breakdowns and repairs

Other responsibilities :

Submit report to the Chief inspector by 10th

ofevery month

Be present at annual inspections

Assist the Inspector in any investigation

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p

An engine driver (boiler operator) needs toknow :

About boilers in general; Every part of the boiler, inside and outside,

including all the fittings and its functions;

How to start the boiler, how to run the boiler,and how to shut down the boiler, and howthe boiler functions;

The essentials of water treatment;

A little bit about boiler maintenance, Boiler house safety, and

The requirements of the law

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HYDROSTATIC TEST

Done at site for the first time during installation

Done to check for leaks or to test its integrity,

e.g. after repairs.

Required once every 7 years. [Regn. 72.(4)]

STEAM TEST

Done at site for the first time during installation,

When the safety valve is changed

At every commisioning

ANNUAL INSPECTION

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Spading (isolating) the boiler attachments e.g. safetyvalves and water gauge, except for the feed water inletand blowdown valves

Use appropriate pressure gauge

Leave one vent open at the top to ensure water

pumped in completely fills the boiler Raise pressure to design pressure. Check.

Raise pressure to 1.5 x design pressure, maintain for

at least 20 mins. Check for leaks. Slight weeping is acceptable (expanded tubes only).

Fill in the hydrostatic test Form JKJ 127 (new boiler).

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Warm up the boiler.

Fire the boiler adequate slow firing. Check.

Raise the pressure to the operating pressure; Check.Increase the pressure;

Bypass the fire cut-off if necessary, to test thepressure relief valves. The highest pressure settingshould not exceed the design pressure. Note theseating pressure.

If provided with superheater, test the superheaterrelief valve first; it should have the lowest setting.

Test the high water and low water alarms.

Ensure safe blowdown; check blow down pit or tank.

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52/60 FITTINGS

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53/60 Statutory Inspection

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What the DOSH inspectors look for:

Signs of shell wall thinning. Cracks at welds and at connections.

Damage to the shell by impact.

Leaking gaskets and seals.

Soundness of foundation.

Protective coatings.

Safety relief valve functions.

Alarm functions Pressure gauge calibration

Hazards such as sumps and blowdowns.

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Dates the boiler was brought into and takenout of commission

Dates cleaned, inspected, tested or repaired Details of alterations and repairs

Every entry initialled by owner and person

making inspection, test or repair

Must be produced when requested by anInspector

(Inspectors comments)

(Log book)

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Act /

Regn.

Section /

Regn.

Details Penalty

RM

FMA

39 (3) &

40 (4)

Not complying with notices 250 K or

5 yrs

40(3) Engineer aware of dangerous

defect, to repair or stop operation

250 K or

5 yrs

19(1) Operating without a valid

Certificate of Fitness

150 K or

3 yrs

31 Not reporting accidents anddamage to machinery

100 K or2 yr

36(1) Installing machinery without

written approval

100 K or

2 yrs

29(1) Machinery not to be operated

without Competent Person

50 K or

1 yr

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FEES FOR STEAM BOILERS based on HS

SQ FT SQ M OLD RM NEW RM

< 50 < 5 25.00 84.00

50 TO 100 5 TO 10 60.00 203.00

100 TO 250 10 T0 25 80.00 270.00

250 TO 500 25 TO 50 100.00 337.00

500 TO 1,000 50 TO 100 120.00 405.00

1,000 TO 2,500 100 TO 250 150.00 506.00

> 2,500 > 250 180.00 608.00

ELECTRODE BOILER, AUTOCLAVE 25.00 100.00

SUPERHEATER 20.00 80.00


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(i) Where Pressure Vessel is under steam pressure and has a cubic capacity -

under 0.1 cubic meters RM 36

0.1 cubic meters and above but under 0.5 cubic meters 54

0.5 cubic meters and above but under 5 cubic meters 90

5 cubic meters and above but under 10 cubic meters 108


15 cubic meters and above 180

(ii) Where Pressure Vessel is not under steam pressure, and is not used exclusivelyfor starting an internal combustion engine, and has a cubic capacity -

under 0.1 cubic meters RM 20

0.1 cubic meters and above but under 0.5 cubic meters 40

0.5 cubic meters and above but under 5 cubic meters 80



15 cubic meters and above 160(1 cu m = 35.3 cu ft)


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(i) any hoisting machine (other than an electric passenger, goods orservice lift or mobile crane) where the aggregate kilowatt of theprime movers installed therein is -

under 15 kilowatt RM 86

15 kilowatt and above but under 37 kilowatt 151

37 kilowatt and above but under 75 kilowatt 194

75 kilowatt and above 237

(ii) any electric passenger or goods lift where the travel of such lift is

under 30 meters RM 173

30 meters and above but under 140 meters 380

140 meters and above483

(iii) any electric service lift 120

(i) anymobile crane146


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FEES FOR INSPECTION OF FACTORIES

Fees shall be charged for an inspection of a

factory (excluding inspection of machinery) atthe following rates:

i. where the working floor area is under 1,395

square meters : RM 193.00ii. where the working floor area is 1,395 square

meters and above but under 4,650 squaremeters : RM 495.00

iii. where the working floor area is in excess of4,650 square meters : RM 873.00

60/60 Jumpa Lagi ...

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