LOT 143 JALAN CECAIR FREE TRADE ZONE

JOHOR PORT 81700 PASING GUDANG

JOHOR

JOHOR SKILLS DEVELOPMENT CENTRE

(JOHOR SKILLS)

STEAM PLANT ENGINEER

PRACTICAL TRAINING
BASF (MALAYSIA) SDN BHD

ME-011-3:2014- CO1/ PA (3/4)

BOILER WATER ALARM TESTING AND
PROCEDURE
1.0 TITLE
BOILER WATER ALARM TESTING AND PROCEDURE

2.0 INTRODUCTION
Originally the water level in a steam boiler was controlled by the boiler attendant
regulating the feedwater inlet valve by hand whilst watching the water level in the gauge
glass. This unreliable method caused many serious accidents, and was the main reason for
regulations requiring automatic controls and alarms to be fitted.
As modern steam boiler design has progressed, the water volume and water surface
area relative to the evaporation rate have decreased. The result is a highly efficient, cost-
effective package that will work well if it is controlled smoothly.

On a steam raising boiler there are three clear applications for level monitoring devices:

 Level control - To ensure that the right amount of water is added to the boiler at
the right time.
 Low water alarm & Low water fuel cut off alarm- For safe boiler operation, the low
water alarm ensures that the combustion of fuel does not continue if the water
level in the boiler has dropped to, or below a predetermined level. For
automatically controlled steam boilers, national standards usually call for two
independent low level alarms, to ensure safety. In the UK, the lower of the two
alarms will ‘lockout’ the burner, and manual resetting is required to bring the
boiler back on line.
 High water alarm - The alarm operates if the water level rises too high, informing
the boiler operator to shut off the feedwater supply. Although not usually
mandatory, the use of high level alarms is sensible as they reduce the chance of
water carryover and waterhammer in the steam distribution system.
 Figure 1: Operating Level for Water Controls and Alarms

3.0 PROCEDURE
1) Wear PPE ( Safety shoes, safety glass, safety helmet, gloves and safety jacket)

Figure 2: Compulsory PPE attire before entering site area

2) Test high water level alarm.

3) Fill up water in boiler by open feed pump valves until reach high water level as in figure
1 or 75-80%
4) Alarm will set off if the water level is overload.
5) Test low water level alarm.
6) Open blowdown valve until low water level.
 7) First low water level alarm will set off if water level reach (40-45%)
8) Push reset button to turn off the alarm
9) Continue blowdown and Low water alarm fuel cut off will triggered when water level
reach (30-35%)
10) Close blowdown valve.
11) Open feedwater pump until the water reach normal water level (>50%)

4.0 REPAIR AND REPLACEMENT

The objectives of the Testing and Commissioning works are:
 To verify proper functioning of the equipment/system after installation.
 To verify that the performance of the installed equipment/systems meet with the
specified design intent and statutory requirements, if any, through a series of
tests and adjustments.
 To capture and record performance data of the whole installation as the baseline
for future operation and maintenance.
 To ensure water alarm works accordingly.

Replace any faulty parts after water alarm testing. E.g; water alarm not triggered even
though water already reach maximum or minimum level.

Figure 3: Testing High and Low-Water Alarm

 5.0 DRAWING, DATA & TABLE
High and Low-Water Alarm
Step Water Capacit Process  Cleaning dirt Action Time
Level y (%)  Tighten if any loose Taken
screws
3 HH 90-95 Partially open bypass Alarm triggered when water 5min
feedwater pump reach HH level. Reset & close
valve. bypass valve.
2 H 80-85 Fully open bypass Alarm set off when water reach H 10min
feedwater pump level. Press reset button and
valve continue infill water
1 NWL 60-65 Low water
Fully open bypass Infill fuel
watercutfrom
off water
low level until 20min
feedwater alarm.
pump reach normal water level before
valve  Cleaning
proceed dirt next process to test
 Tighten
water alarm any loose
if
screws
4 1st 40-45 From HH level, fully Alarm set off once water level at 20s
Low open blowdown about 40-45%. Press reset button
valve. Set feedwater and continue the process
pump in auto position
5 2nd 30-35 From 1st low, 2nd Alarm triggered. Fuel supply 15s
Low partially Mobreywere
open Low cut off.Fuel
Water Close
Cutblowdown
blowdown valve Off Alarm
valve. Boiler will continue to
Typical operate once mounting
water level reach
arrangement.
NWL
 Side and side entry
chamber on horizontal
boiler

Mobrey High and Low Water

Alarm
Typical mounting arrangement
 Side and side entry
chamber on horizontal
boiler
Table 1: Mobrey Directs Mount Models
6.0 TOOLS, EQUIPMENTS AND MATERIALS

No. Equipments Quantity

1 Boiler (15bar with ASWP 10bar) 2

2 Proper Personal Protective Equipment 1 set

3 Tools box 1 set

4 Technical manual 1

5 Water level indicator 2

6 Water gauge glass 2

7 Log Book 1

7.0 TIME
2.00pm-4.00pm

8.0 ASSESSMENT CRITERIA

Work process

1) Wear proper PPE

2) Make sure there is no un-authorised person in testing area.
3) Boiler water alarm is in service and already in normal water level ( 60%-65%)
4) Fill up water in boiler by open feed pump valves until reach high water level as in figure 1 or
75-80%
5) Alarm will set off if the water level is overload.
6) Make sure suction and discharge valve in open position.
7) Feed water pump set in auto.
8) Circulation valve in open position to inlet dearator.
9) Test low water level alarm.
10)1st low water level alarm will set off if water level reach (40-45%)
 11) Open blowdown valve until low water level alarm activated.
12) Close blowdown valve.
13) Push reset button to turn off the alarm
14) Continuous blowdown and 2nd low water alarm fuel cut off will triggered when water level
reach (30-35%)
15) Fully close blowdown valve.
16) Switch on feedwater pump until reach normal water level (>50%)
17) Every 30 minutes monitor water level until reach normal level.
18) Perform 5S after completing test procedure.

Figure 4:Rotating spindle to test water alarm

9.0 ATTITUDE

 Focus fully on the job

 Honest in executing job function
 Follow written work instruction requirement

Dengan ini, pihak BASF (Malaysia) Sdn Bhd telah mengesahkan bahawa pelatih yang bernama

, bernombor kad pengenalan

telah menjalani kursus amali di BASF (Malaysia) Sdn Bhd bertempat di Lot 143 Jalan Cecair

Free Trade Zone, Johor Port 81700 Pasir Gudang, Johor pada tarikh .

Disahkan oleh.

(tandatangan & cop)

Suhaimi Bin Samsudi Tarikh:

Pegawai pemantau Steam Plant Engineer
Johor Skills Development Centre