AGuideforFireTubeBoiler PDF
AGuideforFireTubeBoiler PDF
AGuideforFireTubeBoiler PDF
* Registered with the Boilers and Pressure Vessels Division, Labour Department
* Examined by an appointed examiner and has a valid certificate of fitness
* Supervised by a competent person whenever it is steaming
* In safe working order
* Properly maintained through regular periodic internal examinations every 14
months by an appointed examiner
A Guide for Fire-tube Boiler Operation
Labour Department
May 1993
Printed by the Printing Department
(Printed with environmentally friendly ink on paper made
from woodpulp derived from renewable forests)
FOREWORD
This guide explains the main provisions of the Boilers and Pressure Vessels
Ordinance, Chapter 56, as applicable to fire tube steam boilers. Essentials of
operation are also briefly explained.
This guide is not meant to replace the Ordinance or the maker's manuals
which remain the final authority for regulating operation of this equipment.
On request, the Labour Department will also offer further advice to owners
and operators of such equipment.
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CONTENTS
Page
1. General 7
2. Features of Fire-Tube Boilers 7
3. Flashing Up Procedure 9
4. Testing of Gauge Glass 11
5. Low-water Level Cut-Off Switch 16
6. Steam Pressure Testing of Safety Valve 17
7. Testing of Steam Pressure Switch 18
8. Testing of Flame Detector 19
9. Fire-Tube Boiler Emergencies 19
10. Handling of Boiler Fires 20
11. Important Points for Compliance by workers and Factory Owners 20
12. Enquiries 20
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1. GENERAL
The Boilers and Pressure Vessels Ordinance, Cap.56, controls the use and
operation of boilers. The responsibilities for personnel involved in its use are:
OWNER * apply for registration at least 30 days prior
to its being put into use.
* engrave the registration numb e r allocated
on the boiler in a conspicuous position.
APPOINTED EXAMINER * examine the boiler and its auxiliary
equipment.
* seal the safety valve at the approved
maximum permissible pressure.
* issue a Certificate of Fitness.
COMPETENT PERSON * possesses certificate o f competency issued
by the Authority, Labour Department, for
his co mp e ten ce to operate the type of
boiler he is employed to operate.
* follows cor re c t procedure for operation
and upkeep of boilers.
* supervises the boiler directly at all times
when it is in operation.
* ensures that th e safety valve seal fixed by
the appointed examiner is not broken or
tampered with.
The owner of a boiler can be prosecuted and fined a maximum of $50,000
for operating the boiler:
* without statutory examination or a valid certificate of fitness.
* without direct supervision of a competent person.
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4. TESTING OF GAUGE GLASS
When the boiler is in operation, the steam cocks A, D and water cocks B, E are
open and drain cock C is shut. FIG. 4
(a) First shut both steam and water cocks A, D, B and E . Open drain cock C
to prove that all the gauge cocks are in order. Then, with the drain cock C
still open, cocks B and E should be opened. If water blows out freely from
cock C, cocks B and E are clear. FIG. 4 (A).
(b) Shut off cocks B and E and open cocks A and D with the drain cock C
still open. If steam blows out freely from cock C, cocks A and D are clear.
FIG. 4 (B).
(c) To cross test, close cocks D and B, leaving E, A and C open. If water blows
out from cock C, then E, A and the water-column are in order. FIG. 4(C).
(d) Close cocks E and A leaving D, B and C open. If steam blows out from
cock C, then D, B and the water-column are in order. FIG. 4(D) .
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Possible causes of gauge glass indicating incorrect level
(a) If cocks A and D or steam passage is shut or choked, boiler pressure will
press the water level in the glass higher than the real water level of the
boiler. The water level indication in glass will, therefore, be incorrect.
(b) If cocks B and E or water passage is shut or choked, steam will condense
on upper column of glass and accumulate. The apparent water level shown
can be higher than the actual water level, causing false reading.
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6. STEAM PRESSURE TESTING OF SAFETY VALVE
The safe operation of steam boiler depends on the correct functioning of the
safety valve. The safety valve should be lifted daily with the easing gear to
prevent sticking of valve seat and it should be pressure tested weekly as
follows:-
(a) Shut off main steam stop valve.
(b) Adjust steam pressure switch to a setting slightly higher than maximum
permissible working pressure.
(c) With boiler on maximum firing rate, observe the pressure gauge. When
steam pressure reaches m.p.w.p., safety valve will automatically open to
release steam pressure. That means safety valve is se t correctly and
working. Maximum permissible working pressure c an b e obtained from
the Certificate of Fitness.
(d) If the safety valve does not open when the steam pressure reaches the
m.p.w.p., boiler should be stopped immediately, and the easing gear
operated to release steam and lower the boiler pressure. Call th e
Appointed Examiner for examination immediately.
SAFETY VALVE
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7. TESTING OF STEAM PRESSURE SWITCH
This switch should be checked daily to ensure it is functioning properly. During
the initial start, make sure the boiler can be tripped off automatically when
boiler pressure attains the cut-off value of the pressure switch. Cut off pressure
and differential pressure can be adjusted with the adjusting screw on top of the
switch to suit the requirement of the factory.
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8. TESTING OF FLAME DETECTOR
The detector should be tested weekly to ensure it is in normal working order.
An easy method of testing is by removing the detector head from the boiler and
shielding the sensing head with hand. If boiler trips off automatically, the flame
detector is in satisfactory condition.
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(c) Boiler water should be tested and chemically treated according to
manufacturer's schedule or on the advice of an Appointed Examiner. This
will avoid corrosion and scale formation on heating surfaces. Wastage of
furnace, fire tubes or boiler shell can develop and cause boiler explosion.
Consult an Appointed Examiner for advice.
* All automatic safety devices such as safety valve, pressure switch and
low-water cut-off switches should be tested periodically to ensure they are in
good working condition at all times.
12. ENQUIRIES
* For all enquiries please contact the BOILERS AND PRESSURE VESSELS
DIVISION of the Labour Department. The address is as follows:
Unit 01-02, 20/F, Millennium City 6,
392 Kwun Tong Road, Kwun Tong, Kowloon
Telephone: 3107 3458
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Contact Information Updated - 2015