Recertification of Type B Appliances

Guideline
QLD-1000-ENG-GDL-00003
Integrated Gas
RECERTIFICATION OF TYPE B
APPLIANCES
Review record
Rev Date Reason for issue Reviewer/s Consolidator Approver
Andrew
A 28/05/2015 Issued for review LW
MacFarlane
Andrew David
0 31/12/2015 Issued for use
Macfarlane Stevenson
THE THREE
Review due: 31/12/2016
WHATS
For internal Origin use and distribution only.
Subject to employee confidentiality obligations. What can go wrong?
What could cause it to go
Once printed, this is an uncontrolled document wrong?
unless issued and stamped Controlled Copy or What can I do to prevent it?
issued under a transmittal.
Recertification of Type B Appliances QLD-1000-ENG-GDL-00003
Table of Contents
1. Purpose 4
2. Scope 4
3. Definitions 4
4. Responsibilities 5
4.1 Internal Responsibilities/Accountabilities 5
4.1.1 Mechanical / Electrical Technician and Field Operator 5
4.1.2 Field / Plant Mechanical and Electrical Lead 5
4.1.3 Field / Plant Manager 5
4.1.4 Production Operations Manager 6
4.1.5 Rotating Equipment Lead 6
4.1.6 Rotating Equipment Engineer 6
4.1.7 Commissioning Team 6
4.2 External Responsibilities/Accountabilities 6
4.2.1 Gas Work Authority 6
4.2.2 Approving Authority 6
5. General Overview 6
6. Competencies 7
7. Recertification Process 7
7.1 Requirement for Recertification 7
7.1.1 Modification of Appliance 7
7.1.2 Relocation of Appliance 8
7.1.3 Defective Appliance 8
7.2 Design Submission 8
7.2.1 Deviation Approvals 9
7.3 Installation of Appliance 9
7.4 Commissioning of Appliance 9
7.4.1 Where the Appliance design has changed or modified: 9
7.4.2 Where the Appliance has been relocated: 9
7.5 Final Approval of Appliance 10
7.5.1 Where a new Form PGA733 is issued: 10
8. Record Management 10
8.1 Documentation 10
9. Document Information and History 11
List of Tables
Table 1 Competency Matrix 7
Table 2 Documentation Uploads 10
Table 3 Micro-turbine Type B Compliance Plate 17
Table 4 Generator Type B Compliance Plate 17
Table 5 Stage 1 Preliminary Inspection 18
Table 6 Stage 2 Activation – Run Without Fuel 18
Table 7 Stage 3 Activation – Run With Fuel 19
Table 8 Stage 4 Operation 19
Table 9 Stage 5 Completion 20
Released on 31/12/2015 – Revision 0 - Status Issued for use

Document Custodian is LNG Lead Rotating Machinery Engineer
Origin Energy Resources Limited: ABN 66 007 845 338 Page 2 of 20
Once printed, this is an uncontrolled document unless issued
and stamped Controlled Copy or issued under a transmittal.
Based on template: AUS-1000-IMT-TMP-00001_Revision 1_03/07/2015_Integrated Gas Document and Records Manager
List of Appendices
Appendix A Design Submission 12
Appendix B Recertification Process Map 15
Appendix C Type B Approving Authority Classes 16
Appendix D Example Type B Appliance Compliance Plates 17
Appendix E Commissioning Requirements 18

1. Purpose
This document details the recertification process required when a Type B gas fired appliance is
installed, modified, defected or relocated. It outlines the documentation requirements as well as the
technical aspect of a Type B compliant appliance.
The purpose of this guideline is to ensure that Type B appliances within all Origin Energy Queensland
LNG Facilities remain compliant throughout the asset’s lifetime. The requirement for this guideline
stems from the Type B Gas Appliance Integrity Management Plan (QLD-1000-ENG-PLN-00007)
and also the legislative documents:
 Petroleum & Gas (Production and Safety) Act 2004
 Petroleum & Gas (Production and Safety) Regulations 2004
2. Scope
This guideline applies only to the recertification of the following appliances within Origin Energy
Queensland LNG Facilities:
 Gas turbines
 Gas reciprocating engines
 Gas fired TEG boilers
For the certification of new Type B Appliances, refer to Certification of Type B Appliances (QLD-
1000-ENG-GDL-00002).
3. Definitions
Name Definition
Petroleum and Gas (Production and Safety) Act 2004 (Queensland State
Act
Government)
Body or person appointed by the Chief Inspector to assess and certify type B
Approving Authority gas system design compliance. (Note: Approving Authorities are not employed
by the gas inspectorate)
Queensland Government appointed person that administers Petroleum & Gas
Chief Inspector
related matters. Often referred to as the ‘Technical Regulator’.
Computerised Maintenance Management System. Currently eAMS, the
CMMS
operational (enterprise) Asset Management System (Oracle)
eAMS Oracle Enterprise Asset Management System
DMS Document Management System (Opentext or ETDCS)
All components from the manually operable shut-off valve up to and including
Fuel System
the burners.
An assembly which uses gas to produce flame, heat, light, power or special
Gas Appliance
atmosphere.
Gas Fitting As defined in Schedule 2 of the P&G Act
GWA Gas Work Authorisation as defined in P&G Act [s 728]
IMP Integrity Management Plan
May Discretionary
Must/Shall/Will Mandatory and non-discretionary
OLMS Origin Learning Management Ssytem

Name Definition
Operating Plant As defined in P&G Act [Section 670]
P&ID Piping and Instrumentation Diagram
Petroleum and Gas (Production and Safety) Regulation 2004 (Queensland

Regulation
State Government)
Should Strongly recommended but discretionary
SMP Safety Management Plan
Type A Gas
As defined in P&G Act [Section 724 (1)] & P&G Regulation [Schedule 6]
Appliance
Type B - Class C
Complex device. Gas consumption less than 50 GJ/hr.
appliance
Type B - Class M
Major Projects > 50 GJ/hr
appliance
Type B - Class S
Simple device < 5 GJ/hr
appliance
Type B Gas As defined in P&G Act [Section 724 (3)] (Industrial and large commercial
Appliance appliances)
4. Responsibilities
The following personnel shall assume the primary responsibility for the activities covered by this
guideline:
4.1 Internal Responsibilities/Accountabilities

4.1.1 Mechanical / Electrical Technician and Field Operator
 Responsible for installing, altering, removing, servicing, repairing and testing of Class C and
Class S appliances with a gas consumption of less than 5GJ/hr where certified by the Approving
Authority
 Responsible for the creation and submission of recertification documentation
 Responsible for integrity incident and event reporting
 Responsible for integrity data management
4.1.2 Field / Plant Mechanical and Electrical Lead
 Responsible for installing, altering, removing, servicing, repairing and testing of Class C and
Authority
 Responsible for the creation and submission of recertification documentation
 Responsible for integrity incident reporting
4.1.3 Field / Plant Manager
 Accountable for installing, altering, removing, servicing, repairing and testing of Class C and
Authority
 Accountable for the creation and submission of recertification documentation
 Supports integrity data management
 Supports the completion of internal audit activities
4.1.4 Production Operations Manager

 Accountable for the creation and submission of recertification documentation
 Accountable for integrity incident and event reporting activities
 Supports the accepting of commissioning handover documentation
4.1.5 Rotating Equipment Lead
 Accountable for integrity data management
 Accountable for internal audits
 Supports the creation and submission of recertification documentation
 Accountable for accepting commissioning handover documentation
4.1.6 Rotating Equipment Engineer
 Supports the installing, altering, removing, servicing, repairing and testing of Class C and Class S
appliances with a gas consumption of less than 5GJ/hr where certified by the Approving
Authority
 Supports the creation and submission of recertification documentation
 Responsible for internal audits
 Responsible for completing and submitting any design submissions of recertified appliances to
the Approving Authority
4.1.7 Commissioning Team
 Responsible for handing over all commissioning documentation to the Operations team.
Responsible for submitting all commissioning documentation to the DMS.
4.2 External Responsibilities/Accountabilities

4.2.1 Gas Work Authority
 Responsible for installing, altering, removing, servicing, repairing and testing of Class C, S and
Class M appliances with gas consumption greater than 5GJ/hr where certified by the Approving
Authority
4.2.2 Approving Authority
 Responsible for certifying the design of Type B appliances within their approval class level (based
on gas usage capacity and complexity)
 Responsible for installation of Class S appliances (if GWA also held)
 Responsible for certifying the installation of Class C4 and Class M appliances
5. General Overview
Type B appliances must undertake a design approval process to ensure that the appliance meets the
safety requirements and regulatory obligations of the relevant standards.
There are certain instances where the appliance will be required to be recertified, such as relocation or
modification. For these instances, a design submission may be required to be presented to, and
approved by the Approving Authority.
There are three different classes of appliance based on the gas consumption and complexity which
determines how the appliance is approved and certified.
A competent installer working under a GWA or an installer with appropriate competencies and working
under a SMP must certify the installation of the appliance.
This content will be covered in detail in the subsequent sections.

6. Competencies
All gas work permitted on a Type B appliance must be undertaken by a person deemed competent
under the authority of either a Gas Work Authorisation, or a Safety Management Plan if the appliance
is installed in an operating plant.
Origin employees with the appropriate competencies listed in Table 1 and who have been deemed
competent by the Lead Rotating Equipment Engineer may undertake gas work on appliances under the
Origin Energy SMP.
If a Vendor or Contractor is undertaking gas work on behalf of Origin, they must prove that they have
the approval to conduct gas work for that class of appliance. A list of bodies holding GWAs is available
from https://www.dnrm.qld.gov.au/__data/assets/pdf_file/0003/238638/type-b-gas-installers.pdf
(current at the time of document publishing)
Table 1 Competency Matrix
Type of Appliance Maintain & Repair Commission & Certify Compliance
CPCPGS4023A Install, commission & CPCPGS4023A Install, commission &

service Type B gas appliance, or service Type B gas appliance, or
UEPMNT368A Repair & maintain UEPMNT367A Install & commission
Reciprocating engine stationary gas fuelled reciprocating stationary gas fuelled reciprocating
engines engines
Integrated Assessment Instrument – Type B Install and Commission –
Reciprocating Engine
Gas turbine service Type B gas appliance, or service Type B gas appliance, or
(with a fuel UEGNSG139A Repair & maintain UEGNSG138A Install & commission
consumption of less stationary gas fuelled turbine engines stationary gas fuelled turbine engines
than 5GJ/hr) Integrated Assessment Instrument – Type B Install and Commission – Turbine
Engine
Gas turbine
service Type B gas appliance service Type B gas appliance
TEG boiler
service Type B gas appliance service Type B gas appliance
7. Recertification Process
7.1 Requirement for Recertification

The following process outlines the procedure that shall be followed when a Type B appliance is
required to be recertified.
The recertification process varies dependent on the reason for recertification. Some instances will
require a full design submission to obtain a new Type B Approving Authority Certificate [Form
PGA733(2) AA]. Other instances will only require a new Gas System Compliance Certificate [Form
PGA734] or Operating Plant Compliance Certificate [Form PGA697(3)].
See Appendix B for a flow chart of this process.
7.1.1 Modification of Appliance
Any modification or change to the appliance design that is not covered by the original approved design
submission or changes the safety integrity will require a new design submission to be submitted to the
Approving Authority for approval. This submission shall conform to Section 7.2.
Examples of a design change requiring recertification are:
 Ventilation system modification
 Gas regulator or pressure limit switch set point adjustment
 Exhaust or flue modification, such as explosion relief devices
 Non like-for-like components replacement

 Recorded serial number of engine changes (see below)
Any non like-for-like component replacement shall also follow the Management of Change process as
outlined in the LNG Management of Change Procedure (QLD-1000-BUS-PRO-00005)
If the serial number for the appliance recorded on the Form PGA733, such as an engine number,
changes due to major overhaul or replacement then recertification to obtain a new Form PGA733 is
required.
Replacement of components that are like-for-like are not considered a modification. However, any
piping repairs or if the gas valve train is disassembled for any reason, a new Form PGA734 or Form
PGA697 shall be obtained as defined in Section 7.3.
Once the modification or design change has been approved for installation by the Approving Authority,
the modification shall be installed and tested in accordance with Section 7.3.
7.1.2 Relocation of Appliance
Relocation of an appliance will not require installation recertification [Form PGA734 or PGA697] if:
 An appliance is relocated within the location stated on the Form PGA733 and,
 The original approval was made after 1 January 2005 and,
 The environmental conditions such as ventilation are the same and,
 The appliance has been maintained and serviced in general accordance with AS 3814:2015
Appendix G
However, any of the following situations will require recertification:
 The installation location stated on Form PGA733 changes
 The environmental conditions of the installation change
 The appliance or gas valve train is dismantled for relocation
A new Form PGA733 certificate will be required for appliances where the environmental conditions
change or the location stated on the current Form PGA733 changes. This new design submission shall
conform to Section 7.2. A new Form PGA733 is not required where the appliance is dismantled for
relocation within the location stated.
Once the design submission has been approved by the Approving Authority, the appliance shall be
installed in accordance with Section 7.3.
Every time a Type B appliance is moved, a Type B Appliance Recommissioning FIC shall be
completed and loaded to the DMS. The location of the appliance shall also be updated in the CMMS.
See Section 7 for information on the management of these records.
If the appliance is dismantled during relocation, the installation is required to be recertified and a new
Form PGA734 or PGA697 issued. Dismantling an appliance includes breaking any gas piping
connections downstream of the appliance manual isolation valve. If there are no other changes to the
appliance during the relocation, then only the requirements to satisfy a Form PGA734 or PGA697 are
needed. The appliance shall be relocated, installed and tested in accordance with Section 7.3.
7.1.3 Defective Appliance
If an appliance has been found not to comply with the regulatory standards and has been issued a Gas
System Defect Notice [Form PGA734(2)], the appliance must not be operated until a new design
submission proving that the defect is rectified has been approved. This submission shall conform to
Section 7.2.
Once the submission has been approved by the Approving Authority, the modification shall be installed
and tested in accordance with Section 7.3.
7.2 Design Submission

Where a new design submission is required as outlined in previous sections, the Field/Plant Lead or
Technician with support from the Rotating Equipment team shall complete and submit the submission
to the Approving Authority for approval. This submission shall cover the requirements of Appendix A -
Typical Information and Technical Data of AS 3814:2015 as well as other regulatory standards current
at the time. An example of this submission is listed in 9of this document.

It shall include the previous approved design and outline exactly the scope of changes made to the
appliance. The changes to the safety and operation of the appliance shall be noted as well as any
additional safety requirements. A commissioning or test plan shall be developed to test the changes to
the previous design.
The Approving Authority shall endorse the appliance design submission in accordance with the Type B
Approving Authority Code of Conduct and Type B Gas Device Approval Guidelines and ensure it meets
the requirements of the applicable standards such as AS 3814:2015 and AS 5601.1:2010.
The Approving Authority may be restricted to a certain type or size of appliance and shall only approve
appliances that they are licensed to approve. See 0for a description of these classes.
7.2.1 Deviation Approvals
AS3814:2015 and AS5601.1:2010 are a preferred standards, as such it is possible to deviate from the
standard provided that:
 The deviation is lower risk than the relevant requirement under AS3814:2015 or AS5601.1:2010
 A risk assessment has been performed that demonstrates that the risk is lower than the standard
requirement
 The Approving Authority approves the deviation
 Approval is given by the Chief Gas Examiner via the Approving Authority submitting a notice
under section 7 of the P&G regulation to the Chief Gas Examiner along with the risk assessment
and the qualifications and experience of the persons who performed the risk assessment.
7.3 Installation of Appliance

Installation of the appliance shall take place under a GWA or if the appliance is installed at an
operating plant either under a SMP or a GWA. Both instances require the work to be completed by a
competent person as stated in Section 6.
The installation must be carried out in accordance with the original design approval as well as the
relevant requirements listed in AS 5601:2010 and AS 3814:2015.
On completion of the installation, the installer or a certifier of the installation shall issue a “Gas System
Compliance Certificate” [Form PGA734] if the work is conducted under a GWA. If the installation
takes place under a SMP, then an “Operating Plant Compliance Certificate” [Form PGA697(3)] is to
be issued. Only one of these certificates is required to be issued. See Section Error! Reference
source not found. for information on the management of these records.
7.4 Commissioning of Appliance

Commissioning is also considered gas work and the requirements for competencies are the same as
for the installation of the appliance.
7.4.1 Where the Appliance design has changed or modified:
Commissioning of an existing appliance is required when modifications have been made to the
appliance and these changes need to be tested.
To commence the commissioning process, either an approval for commissioning gas letter or a Type B
Approving Authority Certificate [Form PGA733(2) AA] must have been issued by the Approving
Authority.
During commissioning, all safety interlocks, controls and burner management systems must be tested
to ensure they operate correctly. A Type B Installation and Commissioning FIC shall be completed.
See Appendix Efor commissioning requirements.
7.4.2 Where the Appliance has been relocated:
Recommissioning of an appliance is required when the appliance has been relocated.
A Form PGA733 or commissioning letter is not required for appliances that have already been
commissioned and approved by the Approving Authority as this documentation will not have changed
and will be still current.
During recommissioning, all safety interlocks, controls and burner management systems must be
tested to ensure they operate correctly. A Type B Recommissioning FIC shall be completed. See
Appendix Efor commissioning requirements. This completes the process for recertifying an appliance
that has been relocated.

7.5 Final Approval of Appliance

7.5.1 Where a new Form PGA733 is issued:
Once the compliance certification is complete and upon approving the installation, commissioning and
testing documentation of the appliance which required recertification, the Approving Authority will issue
a new Type B Approving Authority Certificate [Form PGA733(2) AA].
In some instances, such as multiple small engines such as hydrapacks or microturbines, it may be
appropriate for the Approving Authority to issue the certificate prior to the compliance certificate [Form
PGA734] being issued. A compliance certificate is still required to be completed.
A Type B Appliance compliance plate shall be fitted to the appliance and the details included shall
comply with Section 4 of AS 3814:2015. See Appendix Dfor examples of this plate. A photo of this
plate shall be uploaded to DMS and the CMMS.
8. Record Management
8.1 Documentation
Once the Type B Appliance recertification process is complete, all design submissions, testing records
and field installation checklists shall be collated and uploaded into the relevant systems as outlined in
Table 2. This table also lists where initial design documents for the Type B appliance are stored.
Table 2 Documentation Uploads
Document Title Completed by: Uploaded to:

Type B Approving Authority Certificate [Form
Approving Authority DMS & CMMS
PGA733(2) AA]
Gas System Compliance Certificate [Form PGA734] or Installer (GWA holder
Operating Plant Compliance Certificate [Form or competent person DMS & CMMS
PGA697(3)] under SMP)
Designated reference number (asset number) and
Commissioning Team DMS & CMMS
name
Approved AS 3814:2009 Appendix A design
Project Engineer DMS
submission including supporting documentation
Proof of compliance plate/s (photo) fitted to appliance Commissioning Team DMS
Maintenance and inspection schedules Project Engineer DMS
Operations manuals and any other supporting
Project Engineer DMS
documents
Fuel Gas P&ID Project Engineer DMS
Installer (GWA holder
Completed Type B Appliance Installation and
or competent person DMS
Commissioning FIC
under SMP)
Commissioning or
Completed Type B Appliance Recommissioning FIC DMS
Maintenance Team
Standard deviation notice under section 7 of the
regulation as sent by the Approving Authority to the
Chief Gas Examiner, the deviation risk assessment, Approving Authority DMS
the qualifications of those performing the risk
assessment (if the design includes a deviation)

9. Document Information and History
DOCUMENT CUSTODIAN
Position Name
LNG Lead Rotating Machinery Engineer David Stevenson
DOCUMENT HISTORY
Rev Date Detailed Changes made in Prepared Checked Approved
Document
0 31/12/2015 First issue Andrew David
Macfarlane Stevenson

Appendix A Design Submission
Appliance Manufacturer: Synchrotech Controls Pty. Ltd.

184 Flower Street
Northgate, QLD 4013
Phone +61 7 3260 5399
Authorised Appliance Australia Pacific LNG PTY LTD
Installer: Level 3, 135 Coronation Drive
Milton, QLD 4064
Phone +61 7 3867 0202
Appliance Commissioner: Synchrotech Controls Pty. Ltd.
184 Flower Street
Northgate, QLD 4013
Phone +61 7 3260 5399
Installation Details: Australia Pacific LNG PTY LTD
Spring Gully PCF
Kogan – Condamine Rd, Chinchilla QLD
Customer Contact Details: Australia Pacific LNG PTY LTD
Level 3, 135 Coronation Drive
Milton, QLD 4064
Phone +61 7 3867 0202
Number of Burners and Caterpillar G3412 Generator Set
Type: 12 Cylinder Reciprocating Engine
Note - See Attached Engine Technical Data Sheet
Gas Consumption: 4.261 GJ/hr @ Full Load

Gas Consumption at Not Applicable
Ignition for Each Burner:
Air Flow Rate at Ignition Not Applicable
for Each Burner:
Volume of Each 2.25 Litres
Combustion Chamber:
Air Purge Volume: 659 Litres
Air Purge Rate: 56.25 Litres/second
Flue Damper Details: Not Applicable
Explosion Relief Details: Not Applicable
Appliance Marking Plate See attached Drawing 412103: Engine Coupling and Nameplate
Details:
Schematic Drawing of See attached Drawing Q-8235-10-DP-2600: Process & Instrumentation
Valve Train: Diagram
Schematic Electrical See attached Drawing 412004: Genset Wiring Schematics
Drawing:

Purge Time Calculations: All exhaust components have been designed to withstand the
maximum explosive pressure of natural gas irrespective of the fact the
system is open ended.
The exhaust piping is designed not to entrap any natural gas from
reaching the silencer.
The silencer has been designed as explosion proof and has the higher
transfer tube located as high as possible to minimise the potential
amount of gas entrapment to below 10% of the total silencer volume.
The exhaust system is specifically designed to meet AS 3814:2009
Section 5.8.5 ‘A gas engine or turbine shall be fitted with an exhaust
system capable of preventing any hazard to personnel resulting from
the ignition of unburnt gas’ and Section 2.19.1.1 ‘A pre-purge shall
ensure that the concentration of any combustible mixture present in an
appliance is reduced to a safe level by diluting with the purging
medium’.
As we meet the requirements of Section 5.8.5 then no dilution by a
purging medium is required.
Under the circumstance that that the engine has been shut down under
a critical alarm and the spark ignition has not been allowed to continue
during the shutdown the generator control system will purge the system
to the full requirements of AS 3814:2009 even though it is not required.
The purge time calculations:
Cold Crank Speed - 250 rpm
Combustion Chamber Volume - 27 Litres
Exhaust Manifold Volume - 30 Litres
Engine to Flue Volume - 75 Litres
Purge Volume:
= 5 x (27 + 30 + 75)
= 660 Litres
Volume Purged per Second:
= 250 x 27 / 2 / 60
= 56.25 Litres
Purge Time:
= 660/56.25
= 11.7 seconds
Will use 12 seconds.
Calculations of Start Gas Not Applicable.

Rate:
Air Dilution Rates for Not Applicable.
Solvents or Dust:
Ventilation Requirements: Combustion air is drawn from within the canopy
During engine shutdown the ventilation requirements are met through
natural means, which are derived from section 6.4.4.2 of AS
5601:2010.
Natural air supply inlet opening is within 5% of the canopy height from
the floor.
Natural air supply outlet opening is within 5% of the canopy height from
the ceiling.
2
Natural ventilation area required is 150 x 4261 = 639,150 mm
Natural air supply inlet opening size is comprised of 2 off louvered
panels at 370,100 mm2 each and is closed during engine operation by

two hydraulic actuators linked to the pressurised oil circuit. Total free
2
ventilation inlet area is 740,200 mm .
Natural air supply outlet opening size is 678,800 mm2.
During operation the ventilation requirements are met through
mechanical means, which are derived from the forced or induced draft
section of Table 6.2 in AS 5601:2010.
Mechanical air supply is drawn from top-rear of the canopy and
directed downwards this is within 5% of the canopy height from the
ceiling and is therefore not within 5% of the canopy height from the
floor – as required.
Natural air exhaust is removed from the top-front of the canopy and is
within 5% of the canopy height from the ceiling.
Mechanical air supply required is 0.5 x 4261 = 2131 litres/second.
Measured flow rate through canopy is 4935 litres/second with both
ventilation fans running. Depending on the canopy temperature one fan
may be cycled off. The engine shuts down if neither ventilation fan is
operational.
Notes:
The higher mechanical ventilation flow rate into the engine is intended to provide
sufficient circulation of air to compensate for the high level air intake.
This is a low exhaust temperature engine. All exposed surfaces are below the
auto ignition temperature of methane (537°C).
To meet client requirements, gas and flame detectors have been installed within
the canopy as an additional safeguard in excess of the requirements of AS
3814:2015. The gas detectors are infra-red point type and are configured with
the control system to give audible alarm at 20% LEL and shutdown at 40% LEL
for Natural Gas. The flame detector combines both UV and IR sensors to
monitor an area with a 90 degree cone of vision. When both sensors
simultaneously detect the presence of a flame, a shutdown signal is generated.
Failure of the mechanical ventilation is detected by flow sail switches.
In the event that mechanical ventilation fails the natural ventilation damper
is opened (hardwired) to allow natural ventilation. There can be no default
position, the machine will be forced ventilated if the fans are available or it
will be naturally ventilated if they fail.
Flue details: Details:

Vertical discharge exhaust stack attached to silencer.
Flue is constructed from 2mm 316 stainless steel tube.
Flue exit point is approximately 4500 mm above ground level.
Operating Instructions: Operating instructions are included in the Operations and Maintenance
Manual, which will be released to the client prior to handover.
Changes from previous Not Applicable
design:
Additional Safety Not Applicable
Requirements:

Appendix B Recertification Process Map

Appendix C Type B Approving Authority Classes
CLASS S CLASS C CLASS M

Factor/device
(Simple Devices) (Complex Devices) (Major Projects)
type criteria
<5 GJ/hr <50 GJ/hr >50 GJ/hr
Allows for Approving Authority must Approving Authority must
approving be independent1 of be independent of
authority to also installer. installer.
Application/ install devices
Restrictions For C4 devices the Approving Authority must
Approving Authority must also sign off on
also sign off on installed/ installed/constructed
constructed system system including
including commissioning. commissioning.
S1 < 200 MJ/hr C1 <5 GJ/hr Unlimited
Gas usage rate S2 < 500 MJ/hr C2 <10 GJ/hr
restriction S3 <1000 MJ/hr C3 <20 GJ/hr
S4 <5000 MJ/hr C4 <50 GJ/hr
Device Type Criteria
Atmospheric
Yes Yes Yes
Burners
Forced/Induced Yes (up to
Yes Yes
Draft Burners 1000MJ/hr only)
Liquid LPG
No Yes Yes
Burners
Programmable
Electronic No Yes Yes
Systems2
Explosion relief to
No Yes Yes
AS1375
Purge Volume >
3 No Yes Yes
10m
Max Gas Pressure 200 kPa No limit No limit
Unusual
No Yes Yes
Applicances3
1 For Class C Devices, a separate business unit with a separate management structure may be considered to be
independent if approved by the Chief Inspector (see next page).
2 There are no restrictions with respect to electronic flame detectors or flame safeguards provided they are AGA
certified and comply with AS3814:2005 C1 2.26.3. Note Class S does not include any device with a PES system.
3 An unusual appliance is a purpose built “once only” or rare configuration such as a theatrical effect.

Appendix D Example Type B Appliance Compliance Plates
Table 3 Micro-turbine Type B Compliance Plate
Table 4 Generator Type B Compliance Plate

Appendix E Commissioning Requirements

Table 5 Stage 1 Preliminary Inspection
Equipment Task
ALL Check all necessary preliminary approvals have been obtained
ALL Check that the capacity matches the appliance specification

Obtain the operating and commissioning manual, including an appliance wiring
ALL
diagram
Check the gas availability and condition at the appliance inlet, e.g. gas type, pressure
ALL
and temperature
ALL Check any gas over-pressure protection against specification
TEG boilers
Check that any interlocks for multiple fuel firing are as specified
Water bath heaters
Check appliance safety devices: over-temperature cut-out device, vents, relief
ALL
devices, etc.
TEG boilers
Check for interlocks on multiple burner installations
Water bath heaters
ALL Conduct a visual inspection
Check the appliance ventilation for compliance with any applicable requirements, size
and location of openings;
ALL
Or if mechanical ventilation is provided, check the operation of fans and their
interlocks with ventilation openings
ALL Carry out a general safety inspection of appliance area
ALL Check that the flue complies with applicable requirements
Table 6 Stage 2 Activation – Run Without Fuel
Equipment Task
ALL Check that the fuel supply has been isolated
ALL Ensure that isolating valves are closed, i.e. start and main safety shut off valves
ALL Check all valves, joints and components for gas leakage
ALL Set control instruments (e.g. regulators and air pressure switch) to an operational level
ALL Switch on power supply
ALL Check the operation of all fan motors, including the direction of rotation
Prove that all valves operate in the correct sequence, check and set any valve-proving
ALL
provisions
TEG boilers Check the sequence of the burner management system up to lockout, with no start
Water bath heaters gas present
TEG boilers Check that the purge and/or combustion air pressure switch contacts change over
from the no-flow condition to the start-up flow condition, and that the proving
Water bath heaters provisions for both conditions function correctly
ALL Check the purge time, and that the purge is monitored during the entire purge period
Check and verify the exhaust rates, dilution air rates, process flow rates, ventilation
ALL
flow rates etc. are as per specification

Table 7 Stage 3 Activation – Run With Fuel
Equipment Task
Check that the gas supply, burner, appliance, flue, plantroom and process are ready
ALL
for a safe run on gas
ALL Open the appliance manual isolating valve
TEG boilers Ensure the isolation of main gas to the burner by closing the test firing valve or by
Water bath heaters removing the test firing link
TEG boilers
Ensure that air flow for the start flame is adequate
Water bath heaters
TEG boilers
Admit gas to the burner system inlet
Water bath heaters
Gas turbines
Initiate start sequence and ensure turbine/engine fires and idles smoothly
Gas engines
TEG boilers
Switch burner on, establish start flame
Water bath heaters
TEG boilers
Check start rate
Water bath heaters
TEG boilers
Prove the operation of the flame safeguard system for the start flame
Water bath heaters
TEG boilers
Check for reliable ignition of start flame
Water bath heaters
TEG boilers
After the establishment of start flame, introduce main gas and establish main flame
Water bath heaters
TEG boilers
Prove the operation of the flame safeguard system for main flame
Water bath heaters
ALL Check the gas flow rate with the appliance specification
TEG boilers
Re-check the start rate
Water bath heaters
TEG boilers If high/low firing, check the low fire rate and air setting, and check the flame stability
Water bath heaters during transition
Table 8 Stage 4 Operation
Equipment Task
Carry out combustion checks over the operating range of the appliance to ensure that
ALL combustion is appropriate and complies with the requirements of AS 3814:2009 and
the technical regulator
ALL Check and adjust any air pressure switches
ALL Check and set all safety and operating controls
ALL Check the operation of pressure relief devices
ALL Check the operation of all interlocks, including any ventilation interlocks
Check and verify the exhaust rates, dilution air rates, process flow rates and any other
ALL
process flow rates and conditions are as per specification
Check that all covers, such as regulator caps, pressure test point screws, hatches, on
ALL
controls have been replaced
ALL Secure all locking devices

Equipment Task
ALL Conduct any required performance verification or efficiency tests
ALL Conduct any required performance verification or efficiency tests
Table 9 Stage 5 Completion
Equipment Task
Ensure that the appropriate operative, supervisory or maintenance staff, or the
owner/operator, receive the relevant instructions on the following:
1. Burner electrical schematic drawings
2. Burner component details
ALL 3. Operating sequence
4. Adjustments and settings
5. Fault finding
6. Maintenance
ALL Complete the commissioning data sheet and provide a copy to the owner/operator
Record and re-submit any variations to the appliance if these constitute a departure
ALL
from the original specification
ALL Record the gas supply details
Check that safe operating instructions are permanently and prominently displayed
ALL
near the appliance operating station
Check that any necessary post-commissioning approvals, including that of the
ALL
technical regulator, have been completed
ALL Hand over to the operator


Recertification of Type B Appliances

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Guideline

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eAMS Oracle Enterprise Asset Management System

DMS Document Management System (Opentext or ETDCS)

Gas Fitting As defined in Schedule 2 of the P&G Act

GWA Gas Work Authorisation as defined in P&G Act [s 728]

IMP Integrity Management Plan

Must/Shall/Will Mandatory and non-discretionary

OLMS Origin Learning Management Ssytem

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Operating Plant As defined in P&G Act [Section 670]

P&ID Piping and Instrumentation Diagram

Petroleum and Gas (Production and Safety) Regulation 2004 (Queensland

Should Strongly recommended but discretionary

SMP Safety Management Plan

4.1 Internal Responsibilities/Accountabilities

4.1.4 Production Operations Manager

4.2 External Responsibilities/Accountabilities

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Table 1 Competency Matrix

Type of Appliance Maintain & Repair Commission & Certify Compliance

CPCPGS4023A Install, commission & CPCPGS4023A Install, commission &

7.1 Requirement for Recertification

 Non like-for-like components replacement

7.2 Design Submission

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7.3 Installation of Appliance

7.4 Commissioning of Appliance

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7.5 Final Approval of Appliance

Document Title Completed by: Uploaded to:

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9. Document Information and History

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Appendix A Design Submission

Appliance Manufacturer: Synchrotech Controls Pty. Ltd.

Gas Consumption: 4.261 GJ/hr @ Full Load

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Calculations of Start Gas Not Applicable.

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Flue details: Details:

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Appendix B Recertification Process Map

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Appendix C Type B Approving Authority Classes

CLASS S CLASS C CLASS M

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Appendix D Example Type B Appliance Compliance Plates

Table 3 Micro-turbine Type B Compliance Plate

Table 4 Generator Type B Compliance Plate

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Appendix E Commissioning Requirements

ALL Check all necessary preliminary approvals have been obtained

ALL Check that the capacity matches the appliance specification

ALL Check that the flue complies with applicable requirements

Table 6 Stage 2 Activation – Run Without Fuel

ALL Check that the fuel supply has been isolated

ALL Switch on power supply

Released on 31/12/2015 – Revision 0 - Status Issued for use

Table 7 Stage 3 Activation – Run With Fuel

Table 8 Stage 4 Operation

ALL Check and set all safety and operating controls

ALL Check the operation of pressure relief devices