29/8/2023

BAYUBALI ENGINEERING SDN BHD

GOOD ENGINEERING PRACTICE ON

BOILER OPERATION MANAGEMENT

Ir. Ts. Mohd Normarzuki bin Yaacob

1st Grade (Steam & ICE Engineer)

Bayubali – Boiler Safety Training 1

Presenter’s Profile

• Bachelor of Mechanical Engineering.

• Professional Engineer (Mechanical) with Practicing Certificate, BEM.
• Professional Technologist, MBOT.
• 1st Grade Engineer (Steam & ICE), DOSH.
• Field of Expertise;
o Steam boilers and ICE training courses.
o Steam plant energy and cost savings training and consultancy.
o Steam plant upgrading and improvement consultancy.
o Steam piping design and modification.

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BAYUBALI ENGINEERING SDN BHD

Steam System Basics

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Steam System Operation

• There are four categories in steam system components:

1) Generation,
2) Distribution,
3) End use, and
4) Recovery.
• These four areas follow the path of steam as it leaves the
boiler and returns via the condensate return system.

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Steam System Schematic

Generation

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BAYUBALI ENGINEERING SDN BHD

Steam Plant Operator’s

Roles and Responsibilities

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Steam Operator's Roles and

Responsibilities

• Factories and Machinery (Person-In-Charge)

Regulations 2014, Regulation 18B & 18C has
mentioned the overall roles and responsibilities of steam
engineers, and it such as followings:-
o To ensure the operation and maintenance of every
steam boiler and engine, and its associated
machineries are complied with the Factories and
Machinery Act, 1967 and its regulations.
o To enter in the register such as followings:-
− A report on the condition of the machinery and of
the effectiveness of any safety devices fitted to
the machinery periodically.
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Steam Operator's Roles and

Responsibilities

− Details of any repairs required to the machinery

and the dates when the repairs have been
executed, and
− Details of any breakdown of the machinery which
may have occurred and of the repairs effected.
o To ensure the operation, control and safety devices
of every steam boiler and engine, and its associated
machineries are tested on a routine basis and
periodically in accordance with the manufacturer’s
recommendations.
o To check (enter) the logbook and record of steam
boiler and engine periodically.
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Steam Operator's Roles and

Responsibilities

o To ensure that the steam boiler and engine, and its

associated machineries are operated and
maintained in good condition and in a safe manner.
o To be present at every regular inspection of the
steam boiler and engine.
o To advise employer on the needs of any repair or
modifications on the steam boiler and engine.
o To assist an Inspector in any investigation of any
accident connected with the steam boiler and
engine.

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Steam Operator's Roles and

Responsibilities

• Generally, the duties and responsibilities of steam

engineer can be summarized such as followings:-
o To identification basic types of steam boilers,
applicable service conditions, materials of
construction and limitations.
o To outlines loads, pressure-temperature rating and
corresponding materials.
o To describe applicable company specification for
boilers.
o To define boiler vessel in company project including
thermal and dynamic effects.
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Steam Operator's Roles and

Responsibilities

o To propose project specification – boiler pressure

vessel specifications.
o To review tender submission.
o To review and approve design and specification of
boilers using applicable Codes and Standards and
its application to oil and gas industry.
o To guide in application of boilers to process
requirements.
o To applies Codes and Standards for boiler repair and
maintenance.

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Steam Operator's Roles and

Responsibilities

o To be a company expert.
o To provide advice to the employer on the operation,
maintenance, repair, modification and inspection of
the steam boiler and its associated machineries.
o To liaise with the authorities (DOSH & DOE) for any
issues related to steam boiler design, installation,
operation and maintenance (including certificate of
fitness renewal).
o To train engineers and drivers for enhancing their
knowledge and skills.

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BAYUBALI ENGINEERING SDN BHD

Fundamental
Operational Responsibilities

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Operational Responsibilities

• Operators must be familiar with certain fundamentals that

were commonly posted in the in manual operating
systems, among these were the following rules:–
o Water Level
o Low Water
o Low Water Cut–Off
o Gauge Cocks
o Safety Valves
o Burners
o Flame safeguards

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Operational Responsibilities

o Boiler Internals
o Boiler Externals
o Leaks
o When taking a boiler out of service
o Idle boilers
o Purging
o Preparing a boiler for inspections
o Maintain boiler water treatment testing
o Maintain proper blowdown

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Boiler Efficiency

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Assessing Thermal Performance of

Boilers

• Boiler efficiency:-
o Percentage of heat energy input that is effectively
useful in the generated steam.
o Reference standards:-
− BS845 1987
− ASME PTC4-1

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Boiler Efficiency

• The efficiency of a boiler can be determined in two

ways:-
o Direct method – compares the energy output in the
form of useful output (steam) and the energy input in
the form of fuel.
o Indirect method – the efficiency in the difference
between losses and energy input.

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Boiler Efficiency

• Direct method (Input–Output method):-

o Boiler efficiency = 𝑥 100

o Boiler efficiency = 𝑥 100

Where:
ms = mass of steam (kg/s)
mf = mass of fuel (kg/s)
hs = enthalpy of steam (kJ/kg)
hw = enthalpy of water (kJ/kg)
GCV = Gross Calorific Value of fuel (kJ/kg)
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Boiler Efficiency

• Indirect Method (Heat Loss Method):-

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BAYUBALI ENGINEERING SDN BHD

Boiler House Management

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Boiler House Management

• A boiler house is effective when it is operating efficiently,

reliably, and safely.
• Effective boiler house management shall include the
following items:-
1) Boiler logs
2) Blowdowns
3) Chemical treatments
4) Trained operators
5) Boiler maintenance
6) Boiler inspection
7) Spare parts
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Boiler logs

• A boiler log is fundamental for effective boiler

operations.
• Boiler logs help operators, engineers, and managers to
identify both positive and negative trends within their
plant.
• Changes in pressure differentials, increasing
temperature, or higher readings from water tests like
conductivity, are common line items that are monitored
on a boiler log.

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Boiler logs

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Blowdowns

• Performing boiler blowdowns at the correct frequencies

allow for preventing the accumulation of solids that can
deteriorate efficiency along with creating a very unsafe
operating condition.
• A boiler should be blowdown (bottom) for a minimum of
twice a shift.
• Surface blowdown is commonly referred to as
“continuous blowdown” since this type of blowdown is
accomplished by a slow, continuous removal off the top
of the boiler water level.

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Blowdowns

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Chemical treatments

• The chemical treatment program should address the

basic needs of corrosion and scale control in the boiler.
• Proper chemicals at the required dosage allow for
certain contaminants that may be present to be
reduced.
• Chemicals are required to protect the steam boiler
pressure-side’s surfaces from corrosions and scales.

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Chemical treatments

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Auto chemical treatments

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Trained operators

• Well trained boiler operators are critical to ensuring a

safe and efficient operating environment.
• Every boiler operator must learn the fundamentals of
system equipment, startup, and recovery processes
along with common compliance concerns and safety
best practices.

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Boiler maintenance

• The boiler maintenance planning is required for proper

maintenance and to ensure consistent operations, avoid
downtime and focus on employee safety.
• The schedule uniquely breaks down each component
and recommended testing procedures along with how
often it should be checked from daily to weekly, monthly,
semi-annual and annual.
• Additionally, it provides recommendations on certain
categories to be inspected as required, based off the
use of a particular unit.

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Boiler inspection

• Boiler inspections are crucial for any industry that uses

boilers as part of its regular operations.
• Without periodic inspections a flaw in a boiler could go
undetected.
• Over time, that small, undetected problem will worsen,
and could, in the worse case, lead to a catastrophic
failure that could cause an explosion, injuring or even
killing those working nearby.
• Boiler inspections help prevent catastrophic failures by
uncovering and tracking flaws so that proper
maintenance procedures can be followed.

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REF NO : JH PMD 1918

BAYUBALI ENGINEERING SDN BHD DATE : 02/02/2021

JOB NO : P2021/01019/01/2021
CF RENEWAL & INSPECTION ACTIVITY
PAGE 036 OF 17

A B STEAM DRUM COMPARTMENT

DESCRIPTIONS :‐

A. General view of external steam

drum
B. Internal piping and nozzle still in
good condition. Superficial
pitting was noted at its surface.

C D
C. ~D Header weldment still in full
figure condition. Superficial
pitting was noted at its surface

RECOMMENDATION :‐

A-D To be monitored

EQUIP. DESCRIPTION :
TAG NO. : BOILER B PMD NO. : JH PMD 1918
WATER TUBE BOILER
COMPLETED BY :‐ INSPECTED BY :‐ REPORT PREPARED BY :‐ APPROVED BY :‐

SIGNATURE

IR. MOHD NORMARZUKI BIN YAACOB IR. MOHD NORMARZUKI BIN YAACOB
NAME 1st Grade (Steam & ICE) Engineer 1st Grade (Steam & ICE) Engineer

DATE 02/02/2021 02/02/2021

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RP NO : XXXXXXXXXX
BAYUBALI ENGINEERING SDN BHD DATE : 25 MARCH 2022

JOB NO : XXXXXXX
BOILER INSPECTION JH PMD 1249
PAGE : 05 OF 06

DPT RESULT
TUBE NO ACTUAL THK(mm)
NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES
NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES
NO SIGN
TUBE
DISCONTINUITIES

NO SIGN
TUBE
DISCONTINUITIES

EQUIP. DESCRIPTION :
SERIAL NO : 10231 PMT NO. : JH PMD 1249
WASTE HEAT FIRETUBE BOILER
COMPLETED BY :‐ PREPARED BY :‐ REVIEWED BY :‐ APPROVED BY :‐

SIGNATURE

NAME FARHAN ANUAR Ir. MOHD NORMARZUKI BIN YAACOB

DATE 25/03/2022 25/03/2022

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Boiler Spare Parts

• Spare parts inventories can be intelligently reviewed,

and spare parts kept to a reasonable minimum.
• The critical spare parts such as gasket, valve, ignitor
etc. should be kept in boiler house so that any urgent
replacement can be actioned immediately.

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BAYUBALI ENGINEERING SDN BHD

Steam Traps

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Steam Trap

• An important component used in steam systems is a

steam trap.
• There’s three main functions of steam trap:-
o To trap steam from going through and discharging out
into the atmosphere or discharging into a condensate
main.
o To remove condensate or liquid from steam systems.
o To remove air from the system.

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Steam Trap

• There are several steam trap designs such as:-

o Mechanical steam trap – Float and Inverted Bucket
o Thermostatic steam trap – Thermostatic and Bi-
Metallic
o Thermodynamic steam trap
o Venturi nozzle steam trap

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Steam Trap Test Method

• Several methods are used to test the operating condition

of a steam trap to determine if it is working properly, such
as followings:-
o Visual observation
o Measuring temperature
o Measuring sound or ultrasound, and some
combination of these methods

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Cold Traps (Blocked)

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Determine Steam Leaks By Temperature?

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Steam Trap Test by Measuring Sound or

Ultrasound

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Ultrasound Test (TD)

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Ultrasound Test (CMTD)

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Superheater Drain Valve (135 barg)

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BAYUBALI LEARNING SOLUTIONS

Condensate Recovery

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What is Condensate Recovery?

• Condensate recovery is a process to reuse the water and

sensible heat contained in the discharged condensate.
• Recovering condensate instead of throwing it away can
lead to significant savings of energy, chemical treatment
and make-up water.
• Condensate can be reused in many ways, for example:
o As heated feedwater, by sending hot condensate back
to the boiler’s deaerator
o As pre-heat, for any applicable heating system
o As steam, by reusing flash steam
o As hot water, for cleaning equipment or other cleaning
applications
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BAYUBALI LEARNING SOLUTIONS

Steam Pipe Sizing

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Steam Pipe Sizing

• The importance of the steam distribution system is to

pick steam from the steam generator (boiler) and
deliver it to the user section, as per its requirements:-
o Quantitatively, and
o Qualitatively.

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Plant safety, management and maintenance

policy

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Plant Owner’s Responsibilities

• The plant owner is responsible to the followings:-

o Ensure a hazard assessment undertaken prior to
and following the commissioning stage.
o Ensure that effective consultation has been
undertaken with affected workers during the design,
acquisition and purchasing stages of any plant.
o Ensure that operating procedures are available for
workers for each hazardous/duty involving the use of
plant.

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Plant Owner’s Responsibilities

o Ensure that operators responsible for maintaining

plant are competent and have received the
necessary training in order to fulfil their job duties.
o Maintaining of plant is undertaken in accordance
with manufacturer’s specifications and any other
requirements identified, i.e. via a hazard
assessment.
o Provision of appropriate information to the
dismantler or new owner during the
decommissioning, dismantling and disposal stages.

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Plant Owner’s Responsibilities

o Obtaining the necessary training and competencies

prior to undertaking all required tasks associated
with plant.
o Ensure effective hazard management strategies are
in place prior to the use and operation of plant.
o Using the plant only for the purpose for which it is
intended and designed.

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Plant Safety Management

• Conduct regular risk assessments

o The first step toward improved safety is to take a
thorough look at your workplace to identify anything
with the potential for causing harm.
o Hazards could include anything from protecting
employees which is anything that affects the
wellbeing of your employees should be considered.
o Once hazards are identified, a thorough analysis and
evaluation will determine how likely and severe the
potential risks are.
o The decisions can be made on the effective
elimination of the risks.
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Plant Safety Management

• Focus on prevention first

o The prevention-based safety program is the effective
initiative for accident’s prevention compared to than
isolated efforts.
o A thorough accident prevention program requires
regular training, high-quality, industry appropriate
equipment and a company culture that embraces
safety and respect for all workers.
o The benefits of investing time and energy into a good
safety plan include higher job satisfaction, improved
corporate image and staff retention, increased
productivity and efficiency.
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Plant Safety Management

• Develop a culture of safety

o Developing a culture of safety by demonstrating an
expectation of success in every department should
be at the top of the priority list for plant managers.
o Empowering employees to support one another in
reporting near misses and making suggestions for
improvements creates an atmosphere of mutual
respect and personal responsibility.

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Plant Safety Management

• Understand anyone’s responsibilities

o Complying with standards for safety is no small feat
regardless of facility size.
o In addition to industry-related safety measures, it is
anyone’s responsibility to provide the workplace free
from hazards likely to cause death or physical harm.

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Maintenance Policy

• Maintenance is defined as a process in which working

condition of plant or machinery is maintained at the
optimum level as to give maximum output.
• Maintenance is done through repair, partial replacement
and total replacement.
• Maintenance policy shall include the followings
aspects:-
o Maintenance policy ensures that equipments are
always in ready and reliable condition and this
ensures company is able respond to any sudden
change in demand.

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My Contact Information

Ir. Ts. Mohd Normarzuki bin Yaacob

+6019-9196029

normarzuki@bayubali.com.my

www.bayubali.com.my

https://www.facebook.com www.linkedin.com/in/ir-ts-mohd-
/irmohdnormarzuki.yaacob normarzuki-yaacob
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