Steam Boiler BG01 Compliance with Flomar

BG01 Compliance

This is a guidance by M&M Training Services of the requirements of compliance to BG01 and a recommended way forward for your company

To understand what the above implies, you must first understand several key issues;

Typical Arrangement LevelWhat is the current level of automation within the boiler house, please note if you have more than one boiler, there may be a different level for each boiler. The arrangement for the lowest level of automation will apply for the manning levels.

For example one boiler may have external Mobrey Level Controls whilst the other, perhaps a more modern boiler would have high integrity level probes fitted in ‘pots’ mounted into the top of the boiler shell.

Manning LevelsOnce the automation of the boiler(s) and all other associated equipment is known, the required manning levels can be set, i.e. for the highest level of automation, the minimum amount of supervision can be put in place, typically with the boiler house being manned for a period of up to 72 hours and for the lowest level of automation it may be that a boiler operator has to be within the boiler house at all times.

TrainingBoiler Operations – Review of Operator Competence – Requirements;

References;

A. Health and Safety at Work Act 1974B. Provision and Use of Work Equipment Regulations 1998C. Approved Code of Practise – L22 – Safe Use of Work EquipmentD. BG01 - Guidance on Safe Operation of Boilers – Edition 1 – October 2011

IntroductionSteam boiler operation is quite different, due to the hazardous nature of the boilers, from general plant operation. Within the framework of Reference A. (Health and Safety at Work Act) the following supplementary documents refer to the need for adequately trained personnel when dealing with plant and equipment and steam plant in particular; it may be that after carrying out a technical boiler house risk assessment on any individual site further bespoke training courses may be required.In this example, little or no condensate was returned, posing a serious risk to the boiler from hard water, for this reason a further course was inputted teaching oiler operatives how to take water treatment samples and the understanding of the results.It was also agreed that more emphasis should be given to the training on alarms, both critical alarms and urgent alarms, boiler safe entry procedures etc. M&M Training put together a

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bespoke course for this client to teach both water treatment, alarms, panels and boiler house safe entry procedures.Each site needs to be evaluated for the needs for any extra training requirements that are felt necessary, we are more than happy to design a bespoke course to match the sites requirements.

Reference B; Reference Provision and use of Work Equipment Regulations 1998 and the accompanying Approved Code of Practice

Reference C; ACOP L22 -Safe use of work equipmentReference D; BG01 - Guidance on Safe Operation of Boilers – Edition 1 – October 2011

To ensure that all of the above is fully understood a technical boiler house risk assessment needs to be carried out.

Risk AssessmentsThe Management of Health and Safety at Work Regulations 1999 (MHSWR) Regulation 3 requires the completion of a suitable and sufficient risk assessment of the work activity in order to properly identify and adequately manage risks. This is of central importance. The risk assessment is to identify sensible measures to control identified risks that may otherwise result in injury or danger.

This Risk Assessment has to be produced to ensure that the boiler house is in line with the guidance on Safe Operation of Boilers REF: BG01 and INDG436 - Safe Management of Industrial Steam and Hot Water Boilers.

The above document applies to those industrial & commercial steam and hot water boiler plant operating at a working pressure of between 0.5 and 32 bar gauge and working temperature between 110⁰C to 400⁰C.

This risk assessment needs to look at all of the aspects laid down in BG01 and also the ‘wheel’ as shown in INDG 436.

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“The diagram on this page, taken from HSE INDG436 identifies that the achievement of safe boiler plant arises from a combination of factors as identified by each of the spokes of the diagram. All attributes must be properly managed.”

GETTING IT WRONG CAN HAVE SERIOUS CONSEQUENCES

Our Analysis of Training Requirements

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Each site will need to review and discuss the requirement for training and operation of plant.It will probably identify that training and competency assessment is required at several levels.

The levels identified are nominated as; Boiler Manager Senior Boiler Operator Boiler Operator

The duties and responsibilities attributed to each grade are identified in Annex A together with a description of the training and competency assessments for each grade.

In general, competency is gained by completion of; Appropriate training courses, including assessment tests/exams An appropriate period gaining experience, including completing a log book/task book A Practical Assessment by suitably qualified local staff or external personnel

Annex B gives a summary of the courses available from M&M.

At Annex C the requirements of Annex A and course availability of Annex B are brought together in the proposed Training Matrix.

One point to note is that completion of the appropriate training alone is not sufficient for determination of competence. It is the completion of Training, Experience and Assessment that is required.

The key point that comes out of a review, is that safe operation of boiler plant does not necessarily demand that each and every boiler operator is BOAS qualified but does

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demand that each company has a robust process for training and certifying competence of boiler operators.

Ultimately, could the company defend the position in Court? Indeed the BOAS (O) qualification is regarded by some as equivalent to an A-Level in terms of the academic requirements and not all operators would necessarily be able to cope with that level academically, but they would be able to cope with the basic operation of boiler plant.

Proposal of Boiler Plant Training and Qualification Requirements

The revised proposal for manning on a boiler plant is that each site must have; Minimum 1 x BOAS (M) qualified Boiler Manager. Minimum 1 x BOAS (O) qualified Senior Boiler Operator As many as required Boiler Operators, CITB certified and tested for competency, but

not BOAS

It would be possible for one BOAS (M) manager to hold responsibility for more than one boiler site.

Particularly in respect of the Senior Boiler Operators and Boiler Operators this revised approach should;

Provide a shorter and cheaper route to the development of Boiler Operators Prevent the demotivation of personnel who are pushed through for BOAS (O) but may

not be suited to that level Incentivise the BOAS (O) qualified operators to take some direct ownership of the

boiler plant

Annexes;

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A Boiler Operation – Manning RequirementsB M&M Training Services Limited – Steam Training Courses C Boiler Plant Proposed Training MatrixD Boiler Operator Training Record

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Annex A – Boiler Operation – Manning Requirements

The tables below summarises the Functions, Responsibilities and Training Requirements associated with each tier of personnel engaged in Boiler Plant. Tables are:A1 Boiler Plant Manager A2 Senior Boiler Operator A3 Boiler Operator

Table A1 Boiler Plant ManagerFunction Duties/Responsibilities Training Requirements

Boiler Plant Manager Overall responsibility for the management of the boiler plant including:

Carrying out duties of the user as outlined in the Pressure Systems Safety Regulations 2000

Ensuring sufficient trained and competent boiler operators are available

Manage Senior Boiler Operator and Boiler Operators Manage any environmental issues that could impact on the

business Weekly monitoring and signing of the boiler logs, including

water quality testing records. Maintaining adequate and complete boiler records,

including;o Written Scheme of Examinationo Boiler Plant Risk Assessmento Records of maintenance and repairo Ensure all mandatory inspections are carried out in

accordance with the written scheme and manufacturers recommendations e.g. Boiler annual, and 5 yearly, flue inspections, safety valves, pressure vessels etc.

Steam Utilisation Course and CITB test Boiler Operations Course and CITB test BOAS (M) course and exam Competency confirmation by Senior company

manager (Area Manager), making use of appropriate in-house or external assistance

DS Smith

Table A2 – Senior Boiler OperatorFunction Duties/Responsibilities Training Requirements

Senior Boiler Operator Senior Boiler Operator for nominated boiler plant. Duties include:

Operation Starting boiler from cold Connecting boiler to the steam main Normal boiler operating checks and procedures Isolating boiler from the steam main Lay-up boiler when out of service Fault finding to Intermediate/Advanced level Monitor boiler / system performance for potential impact on

site operation

Maintenance: Maintaining Boiler Records, Daily and Weekly logs Carry out boiler checks in line with site procedures based on

BG01 Arrangement 3 and log results:o Evaporation Test (weekly)o Low level water cut out test (weekly)o Gauge glass blow down (daily)o Feed and boiler water test (daily)

Adjust feed/boiler water dosing based on water quality tests

Training: Training and Supervision of Boiler Operators for the

achievement/maintenance of appropriate boiler operating standards

Carry out the competency Assessment of Boiler Operators

Steam Utilisation Equipment Course and CITB test Boiler Operations Course and CITB test Alarms, Fault Finding, water treatment and testing

course 6months / 100 hours documented experience Completed Boiler Operator ‘Task Book’ BOAS (O) course and exam Practical assessment conducted by BOAS examiner

and Senior Boiler Operator, confirmed by Boiler Manager

DS Smith

Function Duties/Responsibilities Training RequirementsBoiler Operator Boiler Operator for nominated boiler plant. Duties include:

Operation Starting boiler from cold Connecting boiler to the steam main Normal boiler operating checks and procedures Isolating boiler from the steam main Fault finding to Basic/Intermediate level

Maintenance Maintaining Boiler Records, Daily and Weekly logs Carry out boiler checks in line with site procedures based on

BG01 Arrangement 3 and log results:o Evaporation Test (weekly)o Low level water cut out test (weekly)o Gauge glass blow down (daily)o Feed and boiler water test (daily)

Adjust feed/boiler water dosing based on water quality tests Report any unusual circumstances to the senior boiler

operator

Training Training of First Response Call Out personnel on the

nominated boiler(s)

Note: Prior to the confirmation of Competency Assessment a Boiler Operator may only carry out the above tasks under the supervision of a Senior Boiler Operator.

Steam Utilisation Course and CITB test Boiler Operations Course and CITB test Alarms, Fault Finding, water treatment and testing

course 3 months / 50 hours documented experience Completed Boiler Operator ‘Task Book’ Practical assessment conducted by Senior Boiler

Operator, confirmed by BOAS (M) Boiler Manager

DS Smith

M&M Training ServicesTraining Brochure 2015/16 Steam & Process Training Courses

DS Smith

IntroductionFor over 30 years M&M Training Services have been providing training in the Steam and Process Market. We have our own purpose built training centre in Leicestershire.

Training Centre

Glass Working Models

We can also provide training at our clients’ facility. We are a member of the CEA, and act on its Council. We are part of the BOAS Working Group. We are an approved training centre for the CEA.We also have certification with the Construction Industry Board (CITB), now called C-Skills.

DS Smith

Courses Available

Course Type External Accreditation Course Duration

A Steam Awareness Course 1 day

B Steam Utilisation Course CITB (C-Skills) 1 day

C Boiler Operator Course CITB (C-Skills) 1 day

D Boiler Alarms Response and Fault Finding plus Water Treatment and Testing 1 day

E BOAS Cat 2 Steam Boiler Course Gastec 4 days

F BOAS Cat 1 Hot Water Boiler Course Gastec 4 days

G Steam Equipment Maintenance Course 1 day

H Boiler House Risk Assessment 1 day on site2 days off site

J Steam Audits TBA

K Refresher Courses CITB (C-Skills) / Gastec 1 or 2 days

L Bespoke Courses TBA

Industries That Should Attend This Formal Training

Food and beverage Laundries Corrugating plants Abattoirs Hospitals Public works departments Petrochemical plants Sewage treatment plants Facilities management companies Motor manufacturers Tyre manufacturers Contractors Project engineers Equipment manufacturers involved in steam

All companies that have a steam boiler on site must give adequate training on the boiler plant.

Most accidents and boiler failures are attributed to operator error.

Most insurance companies insist on formal documented training.DS Smith

Please find below a resume of the course contents;

Steam Awareness Course

Seminar Length: 1 dayMaximum number of delegates at the client’s site: 10 persons

Who should attend?This course is intended for personnel that are new to steam and boiler systems OR for plant operators, production personnel and site staff who may be involved in the isolation and reinstatement of the steam system to areas of the plant and machinery It gives a basic insight to the boiler house and associated equipment, basic plant awareness and current legislation.

AimsTo ensure that all personnel involved with steam equipment understand the principles and effects of steam, how and where steam is formed, the effects of steam and condensate within the system and the safety implications.

Contents Boiler house equipment & layout Boiler Hot well & feed pump Water treatment system How steam is formed Steam tables Saturation curve Pressure & temperature relationship Basic steam and condensate loop Steam distribution & headers Pressure reduction Benefits of condensate recovery Condensate recovery methods Safety Boiler manning levels (BG01 guidelines) Isolation of a steam system Introducing steam into a system Health & safety responsibilities of employer and employee

DS Smith

Steam Utilisation CourseCITB (Construction Industries Training Board) (C-Skills) Accredited


Who should attend?This course is intended for all personnel that are involved with steam plant and are responsible or may become involved with the installation or maintenance of steam equipment. The course covers the relevant mandatory regulations and Health and Safety guidelines.

AimsTo ensure that all personnel involved with steam equipment understand the principles of steam and are able to recognise how steam equipment should be sized, installed and checked to give maximum efficiency and operate safely.

The course covers all manufacturers’ equipment and is totally unbiased to types of equipment supplied. Delegates can be from mechanical or electrical backgrounds.

The delegates are given the opportunity to take a C.I.T.B. examination which is a recognised qualification and is valid for 5 years. If your engineers do require the CITB Test, please ask them to bring a passport size photograph and their National Insurance Number

Content The basic principles in raising steam Health and Safety regulations Pressure Safety Standards Regulations Steam trap operation and types Installation and sizing of steam and condensate mains Operation of pressure reducing valves Maintenance safety procedures Practical demonstration of trap types and checking Basic principles of good working practice CITB Test

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Boiler Operators CourseCITB (Construction Industries Training Board) (C-Skills) Accredited


Who should attend?This course is intended for all personnel involved with the running, management and maintenance of steam and or hot water boiler plant. The course covers all the mandatory requirements around the boiler.

AimsTo give a good understanding of the operation of steam and hot water plant and to ensure operators are aware of the mandatory requirements surrounding the operation of a steam boiler including BG01 guidelines.

The delegates are given the opportunity to take a C.I.T.B. examination which is a recognised qualification and is valid for 5 years. If your engineers do require the CITB Test, please ask them to bring a passport size photograph and their National Insurance Number.

Content The basic make-up of the steam boiler Operation of gas and oil burners Water treatment Boiler operation Mandatory & BG01 guidelines Boiler log TDS and blow down operation Safe isolation of the boiler and boiler lay-up Annual checks Fault finding Practical test CITB test

DS Smith

Panel Alarms, Response and Fault Finding plus Water Treatment and Testing Course


Who should attend?This course is intended for personnel that are new to steam and boiler systems OR for plant operators who need to respond to boiler alarms, it gives a basic insight to the boiler house operation and boiler alarm conditions.

Boiler operators who as part of the operation carry out feed and boiler water checks.

AimsTo ensure that all personnel involved with responding to boiler alarm conditions understand the safety implications when entering a boiler house and the process to follow in order the make the boiler house safe. Carry out fault finding procedures, resolving the issues and re-instating the boiler to ensure that all personnel that carry out water treatment testing understand the science and processes to maintain the correct water quality.

Contents

Boiler Panels Remote on site Remote off site Critical alarms Secondary alarms Operator response Entering a boiler house safely Fault finding and diagnostics

Water Quality Testing Raw water Treated water Hotwell Feed water Boiler water Documentation Quality test procedures Results analysis Carrying out adjustments

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Boiler Operation Accreditation Scheme (BOAS) Cat 2 Steam Boilers

Seminar Length: 4 daysMinimum charge for Gastec at a client’s site: 4 personsMaximum Numbers at a client’s site: 8 persons

What is BOAS?The Boiler Operation Accreditation Scheme (BOAS) provides national accreditation for industrial boiler operators and boiler plant managers, a course recommended by BG01 ‘Guidance on the Safe Operation of Boilers’.

M&M Training Services is a licensed and approved BOAS training provider. The BOAS course provides training to the BOAS syllabus and includes the written examination.

Candidates are also interviewed by an accredited assessor during the course.

Successful candidates may use the designator letters "Cert IBO" (Certified Industrial Boiler Operator) or "Dip BOM" (Diploma in Boiler Plant Operation Management). Candidates from both award categories take the same course and written papers. Interviews are specific to each award. The awards are valid for 5 years, after which a refresher course becomes necessary.

Who Will Benefit?This course is suitable for:

Boiler operators with hands-on experience (evidence must be provided) Boiler plant managers and supervisors (no hands-on experience required)

Those new to the boiler house wishing to have introductory boiler training should consider our Boiler Operators course.

Objectives To train and prepare candidates for the BOAS qualification To promote safety and energy efficiency in the boiler house with due regard to environmental

aspects and legal requirements

Delegates Will Learn About Heat and heat transfer Boilers and auxiliaries Feed water Draught and combustion Control and instrumentation Fuels Safety and legal Energy efficiency Environmental Operation

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BOAS (O) Cat 2 - Full Assessment of the Competence of Boiler Operatives Pre-requisitesThis assessment of competence requires no formal qualifications, although applicants are expected to be in current employment within (or have ready access to) a boiler house.

Candidates will be expected to present a record of their training, and candidates are warned that without some recent up-skilling the assessment may be difficult to pass.

The Assessment ProcessThe assessment is in three distinct sections;

1. Five written papers containing a mixture of text and multiple choice questions on all aspects of boiler house operation. This covers only the principles and is applicable to all 4 categories. This can be sat at Gastec at CRE Ltd Cheltenham, at any approved training centre; or at the client’s site.

The following test papers are closed book; Paper 1 - Boiler, Heat and Heat transfer concepts, Draft & Combustion Paper 2 - Feed water, control and instrumentation Paper 3 - Safety and Legal Paper 4 - Energy Efficiency and Environment Paper 5 - Operation and fuels

2. Completion of an evidence pack (work record or log book) at the operative’s boiler house.

This will include compilation of:- Schematic of boiler plant and steam range All of the other details of the plant described above Details of the boilers themselves Outline of routine actions carried out by the candidate Details of all non-routine actions carried out by the candidate

3. An onsite assessment by a BOAS assessor. This will include review of the written papers, the evidence pack and a spot audit to verify the candidate’s practical expertise.

4. The pass mark is 70%, except on the safety paper where the mark is 100%. For the paper candidates will be expected to achieve at least 80% in the written although they will be allowed to revisit deficient answers during the onsite assessment.

AssessorsAll BOAS assessors will have suitable boiler house experience.

CV’s of staff will be approved by the CEA.

DS Smith

Steam Equipment Maintenance Course


Who should attend?This course is intended for all personnel that are involved with steam plant and are responsible or may become involved with the installation or maintenance of steam equipment. It also aims to train personnel on the symptoms involved with the failure of equipment.

AimsTo ensure that all personnel involved with steam equipment understand the principles and effects of steam on the equipment used. Including fault finding and repairs.

Contents Pipe, Flanges and gaskets Steam trap maintenance Pressure reducing valves maintenance Maintenance safety procedures Bellows sealed valves Piston valves Parallel slide valves Steam trap testing Pressure relief valves Strainers Condensate recovery units Pumping traps

Risk Assessment In line with BG01 Guidance on Safe Operation of Boilers

Enersol Flomar and M&M Training Services Ltd are able to offer an independent risk assessment of your Boiler House. We have professional and competent engineers who are able to carry out the Risk Assessment and provide you with a written report. Should there be any issues with your site meeting the current guidelines, we are also in a position to either: offer you the equipment needed, or to carry out a full mechanical and electrical turnkey project.

Legal Responsibilities – Risk Assessments – For New and Existing SitesRegulation 3 of Management of Health and Safety at work Regulations requires that a ‘suitable and sufficient’ risk assessment be carried out before the work activity commences. Its purpose is to determine whether any risks are present and, if they are not adequately managed, what further control measures are required. The significant findings of the risk assessment must be recorded where there are 5 or more employees.

The control measures must have the primary aim of eliminating the risks. Where elimination is not possible, the control measures should aim to reduce the risks to a level as low as is reasonably practical (ALARP). Regulation 4 and Schedule 1 of MHSWR sets out the principles of prevention.

The responsibility for the risk assessment lies with the employer although he may do this using input or assistance from various sources such as boiler manufacturers and control system experts, or have the entire risk assessment carried out on his behalf by someone competent to do so.

For A Boiler, the Risk Assessment Should Consider Issues Such AsThe likelihood and severity of injuries from;

Burns from: hot water, steam, burners and flues Electric shock Fuel escape Fire Asphyxiation, and toxic effects from combustion products

The location of the boiler with respect to; Proximity to industrial premises/workers Proximity to the public especially vulnerable populations - such as in: nurseries, schools,

hospitals, care homes etc The potential impact on neighbouring sites due to an incident

Capability of safety-related systems Level of supervision The positioning of alarms and the associated response times The presence of other dangerous materials The adequacy of boiler house ventilation and flue integrity Environmental effects, e.g. noise, pollution Effect of chemicals on workers, environment and others, e.g. water treatment chemicals

Operational Risks: Mechanical or water damage to plant or equipment Water-side explosion due to catastrophic failure of the pressure envelope Combustion explosion caused by unspent fuel

Since risk assessments must assess the existing control measures, they should also consider information regarding:

Manning levels Type and reliability of controls and the integrity of safety-related systems Additional controls for remote or unsupervised boiler operation

Risk assessments must be reviewed periodically and when there is a significant change e.g. a system variation, change in operating parameters or manning levels etc. The outcome of any reviews should also be recorded.

As an example, an owner moving from a manned boiler to an unmanned boiler should, as a first step, review the boiler design and the current/ recent risk assessment to take account of the planned change in manning levels. The results of the risk assessment will be used to determine any measures necessary to ensure that the boiler remains safe to use and operate. Such measures may include:

The proper formulation and correct application of all modifications and installations to ensure they have sufficient safety integrity to adequately control the risk of a dangerous occurrence

Amendment of procedures where appropriate to ensure the plant continues to be operated safely

All personnel on-site & off-site and surrounding property remain safe

Steam & Condensate Audits

Steam Generation EfficiencyWith energy prices increasing, improving the boiler and plant efficiency is vital to reducing energy, water and chemical costs.

Enersol Flomar is able to provide a consultative service backed up by being able to fully turnkey project manage any works required to improve the boiler and plant efficiency should it be required.

Our experience allows us to maximise your efficiencies in a manner that allows the client to choose a step by step programme based on (where possible) ROI (return of investment).

The first step in improving your efficiency is to undertake a Steam and Condensate System Audit.

Steam and Condensate System AuditThe audit which is customised for each individual client investigates areas from the following criteria;

Catalogue key equipment Design of distribution system and condensate return system (steam traps, drop out points, pipe

sizing etc)

Steam trap survey This will show leaking or blocked traps. Losses shall be shown in kilograms per hour along with

cost

Establish Flue Loss Consider economisers

Establish Blow down Loss Consider automated blow down

Establish TDS Loss Consider automated TDS control

Establish Hotwell / Feed Water Temperature Consideration given to raising hot well temperature via steam injection and or TDS heat

recovery. Other methods are also considered dependent upon the client’s installation

Establish radiated heat loss (boiler ends, pipe work, valves) Consider lagging options

Establish burner efficiency Consider Replacing mechanical or linked burner controls with modern independent motor-

driven fuel air-mixture controls Consider fixed speed fans and motors with variable speed units Consider reducing burner size on a boiler that consistently runs below optimum load Consider sequencing multiple boilers using a boiler management system controlled by a plant

management programme

Establish Production Steam Load Requirements Consider a load balancing system which will determine when an additional boiler should be

brought online as well as which units will be most efficient at given total load

Establish Current Operating Parameters Consider Operating “No Cost” Operating Improvements

Health and safety recommendations Consideration given to INDG 346, BG01, PM60 and Safed regulations

Report DeliverablesA report will be issued to the client and dependent upon the level carried out to - will deliver the following information;

Inventory of equipment Current boiler efficiency Recommendation of areas of improvements Cost of improvement Return of investment (where applicable) Efficiency % improvement Overall efficiency after recommendations has been carried out.

Benefits of Steam and Condensate System Audit Energy savings Quality improvements Productivity improvements Reduced maintenance Fewer breakdowns Improved Health and safety A focused route to cost reductions

Annex C – Company Boiler Plant proposed Training Matrix Table C1 Training Matrix

Grade Courses Practical ExperienceFinal

Assessment

Re-Qualification

Boiler Manager Steam Awareness Course (A)

Steam Utilisation Course (B)

Boiler Operator Course (C)

Boiler Alarms Response and Fault Finding, plus Water Treatment and Testing (D)

BOAS Cat 2 Steam Boiler Course (E)

No specific experience required, but the candidate will need to demonstrate an understanding of the principles of operation; and provide evidence prior to the BOAS course that they have witnessed / signed off boiler house procedures as per Annex D

BOAS (M) exams and Oral Assessment

BOAS (M) re-qualify at 5 year intervals

Senior Boiler Operator

(SBO)

Steam Awareness Course (A)



BOAS Cat 2 Steam Boiler Course (E)

6 months or 100 hours.

Completion of Boiler Operations Log Book / Task Book / Check Sheet

BOAS (O) Exams and Oral Assessments

BOAS (O) re-qualify at 5 year intervals

Boiler Operator Steam Awareness Course (A)



Boiler Alarms Response and Fault Finding, plus Water Treatment and Testing (D)

3 months or 50 hours.

Completion of Boiler Operations Task Book / Check Sheet

CITB (C-Skills) test at Boiler Courses.

Oral / Practical assessment by SBO.

CITB re-qualify at 5 year intervals.

Local reassessment by SBO when CITB is in date.

Training Cycle

The basic training cycle for boiler plant operators and associated position is as the drawing Figure C1 below. The particular requirements for each grade of person are identified in Table C1 above.

Figure C1 Training Cycle

Re-qualification

Log Book/Task Book

QualifiedAssessmentPractical experience

F

ormal Training

Courses

Annex D - Boiler Operator Training Record

This Training record forms the basis of a Log Book /Task Book for completion by Boiler Operators and Senior Boiler Operators to demonstrate their competence in Boiler Operations.

Operator’s NameAssessor’ Name

DEMONSTRATE HOW TO CARRY OUT THE FOLLOWING TASKSRef Task DATE Sign Off By1 Identify the boiler fittings & mountings2 Starting a boiler from cold3 Starting a warm boiler4 Connecting a boiler to the steam main5 Shutting down a boiler6 Crowning off a boiler7 Blowing down the boiler in manual control8 How to over-ride the automatic blow down valve9 Blowing down the gauge glasses10 Carry out an evaporation test11 Checking the burner flame detector12 Reading the TDS value13 Demonstrate how to use the sample cooler14 Operate the automatic valves from the control panel15 Responding to alarms16 Accepting the boiler panel alarm17 Understanding the boiler panel alarms18 Your action in the event of a fire in the boiler house19 How to isolate the fuel supplies20 Isolating the electrical supplies to the boiler21 Filling out the boiler house log sheets22 Demonstrate how to put the economiser on line23 Demonstrate how to bypass the economiser24 Demonstrate how to take economiser readings25 Checking the hot well level26 Draining down the hot well27 Checking the hot well temperature28 Checking the feed pumps29 Starting and stopping a feed pump30 Checking the chemical tanks & pumps31 General house-keeping tasks32 Checking the boiler house traps33 Reading the steam meter total & rate34 Reading the gas meter35 Reading the make-up water meter36 Drawing and test off raw water to boiler plant37 Draw off and test feed water to boiler38 Draw off and test boiler water39 Adjust water treatment to achieve correct water quality

Engineering

Steam Boiler BG01 Compliance with Flomar