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Steam Engineer Grade 1 and 2 Training

Steam Engineer Grade 1 and 2 Training

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Published by malikldu
boiler info
boiler info

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Published by: malikldu on Mar 15, 2010
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01/26/2013

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STEAM ENGINEER GRADE 1 AND 2 TRAININGCOURSE
Presented by;MohdShafarudinAbdul RasoolSteam / ICE Engineer Grade 1Dip. Mech. Engg(UTM), B.Sc. in Mech. Eng.(UTM), M. Sc. B.E.M(Warwick, U.K), Ph.D(UTM)
PART ONE -IntroductionWhat is our objective?
To facilitate the Engineers who wish to sitfor The Steam Engineers’CompetencyInterview/Examination by The Departmentof Occupational Safety and Health (DOSH)
Who is DOSH?
 A doctor?
 A lawyer?
 A teacher?
 A policeman?
 All of the above ornon 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 PenerajuKeselamatandanKesihatanPekerjaTerunggul
Mission –Make sure Safety and Health of Workeris taken care
Objective –Prevent Industrial Accidents andOccupational 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’reinnocent or to punish if we’re guilty?
To teach us the procedure?
 As an authority?
 As a busybody?
So, what……….?
Since they are theauthority and their job isto police us;
So we need to knowwhat are the rules, theLaws and Regulation…
So than we don’t violatethem!
What this has to do with SteamCertificate?
Well, similar with many other stuff….it is amean to control.Since to operate a boiler require certainskills and knowledge, thus the boileroperator need to be ascertained that theyposses the prerequisite skills andknowledge.
 
These are what we are going tolearn….
 About Act and Regulations…….
Something about Boilers……..
Some guidelines about Boiler Operationsand Maintenance…….
 A bit about Boiler Water Quality……
Laws & Regulations-OVERVIEW
•Health and Safety Legislation, ‘94•Factories and Machinery Act (Act139) ‘67 –Currently OSHA•Petroleum (Safety Measures)Act.1984
PerakBoiler Enactment 1903
Machinery Ordinance 1953
Factories and Machinery Act 1967
Occupational Safety and Health Act 1994
History………..The Act covers…..
MACHINER-Includes Steam Boiler , Unfired Pressure Vessels, Prime Movers, Gas Cylinders, GasHolders, Hoisting Machines, TransmissionMachinery, and Driven Machinery .ALSO INCLUDED ARE ;-Any equipment for the casting andwelding of metals ,the spraying bycompressed gas / air of metals / othermaterial.
The Act does not cover ….
Machinery used for propulsion for vehiclesexcept for Steam Engine / BoilersMachinery driven by manual power , excepthoisting machinesMachinery used solely for Private &Domestic purposes.Office Machines .
Well , what have welearned 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 HealthArt / Factories and Machinery Art ?
PART TWO Laws & Regulation
FACTORIES ANDMACHINERY
(Boiler and UnfiredPressure Vessel)1970.
What we are going to learn ….
•Some Terminologies according to the act•Under what circumstances do we need toliaswith DOSH ?•Under what criteria do we need to haveSteam 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 closedvessel in which for any purpose steam isgenerated under pressure greater thanthe atmospheric pressure, and includesany economiserused to heat water beingfeed to the boiler , and any superheaterused for heating steam , and any pipesand fittings connected there to .
 
 Authorized Safe Working Pressure
means the maximum permissible pressureat which a steam boiler or unfired pressurevessel may be operated as assigned by theChief Inspector and as stated on thecurrent certificate of fitness relating to suchsteam boiler or unfired pressure vessel; “Chief Inspector”and “Inspector”meanofficers appointed under section 4 ( 1 ) of the Act .
Design Pressure …
 “Design Pressure”means the maximumpressure at which the manufacturer of thesteam boiler or unfired pressure vessel orany fittings or pipe work associated therewith designed to operate .
Inspecting Authority …..
 “Inspecting Authority means , in respectof any steam boiler or unfired pressure vessel, an Inspecting Authority named in the FourthSchedule to these regulations .
What is the job of the Inspecting Authority ?
Review the design drawing prior tosubmission to DOSH .Carry out Quality Control inspection duringManufacturing / Construction.Witness ( on behalf of DOSH –withpermission ) any essential testing .
Dangerous Occurances
We also have to inform DOSH when thereis;ExplosionStructure FailureLoss of Boiler WaterBoiler Tube burstFusible Plug burst
Critical Maintenance
We have to inform DOSH ;
When the maintenance involves welding,patching or riveting1.Must be done by qualified welder2.Repair procedure submitted3.This does not include normal maintenancework or tube replace of less than 10% (plug)
Periodical Inspection
For all certificated items( those with PMD’s, PMT’sas well as PMA’s) ;Every interval of 15 monthsExtension can be requested up to 36months
BOILER Vs. CERTIFICATED STAFF
BOILER(S) HEATINGSURFACE OR OTHER AGGREGATE HEATINGSURFACE
< 500 sq. ft.If more than 1 boiler or More than 1 steamengine.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 steamengine.
CERTIFICATED PEOPLE REQUIRED
2
nd
gradeor 1
st
grade driver, or 1
st
/ 2
nd
driver to assist .
1st grade driver, other driver to assist1st /2nd grade Visiting Engineer 1st grade drive1
st
Grade / 2
nd
Grade Engineer 1
st
/ 2
nd
grade driver to assist .

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