Standard
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AS 2593-2004
[Available Superseded]Boilers — Safety management and supervision systems
Specifies the requirements for the operation of boilers, including unattended, limited attendance and fully attended. It includes the special features within the control, management and supervision systems, associated valves and fittings, housing and installation for those boilers operating in the unattended or limited attendance modes.
Published: 28/06/2004
Pages: 69
Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
1 Scope and general
1.1 Scope
1.2 Referenced documents
1.3 Definitions
1.4 New designs, materials and construction methods
2 Design and construction for unattended and limited attendance boilers
2.1 General requirements
2.1.1 Basic design
2.1.2 Tube diameter
2.1.3 Water gauges
2.2 Steam boilers (other than electric boilers)
2.2.1 General
2.2.2 Water-tube steam boilers
2.2.3 Steam boilers other than water-tube or electric boilers
2.3 Hot water boilers
2.3.1 General
2.3.2 Hot water systems
2.4 Waste heat boilers
2.5 Electric boilers
2.6 Superheaters
3 Boiler management system for unattended and limited attendance boilers
3.1 General
3.2 Fail-safe techniques
3.3 Temperature suitability of components
3.4 Combustion management
3.4.1 General
3.4.2 Power-operated valves
3.4.2.1 Fail-safe design
3.4.2.2 Closing time
3.4.3 Flame detectors
3.5 Water management systems
3.5.1 Blowdown
3.5.2 Feedwater supply
3.5.3 Steam boilers, other than coil-type forced circulation boilers and electric boilers
3.5.3.1 General
3.5.3.2 Water level controls and safety devices
3.5.3.2.1 Low level water safety devices
3.5.3.2.2 Automatic water level controller
3.5.3.2.3 Externally fitted water level device other than gauge glasses
3.5.3.3 Feedwater pumps
3.5.3.4 Assisted circulation
3.5.4 Water management systems for coil-type forced circulation boilers
3.5.4.1 General
3.5.4.2 Overheating interlock
3.5.4.3 Water circulation pump
3.5.4.4 Feedwater pumps
3.5.5 Water management systems for hot water boilers
3.5.5.1 General
3.5.5.2 Low water safety devices
3.5.5.3 Water circulation pump
3.5.5.4 Safety thermostat or pressure switch
3.5.6 Water management systems for waste heat boilers
3.5.7 Water management systems for electric boilers
3.5.7.1 General
3.5.7.2 Water level controls and safety devices for electric element boilers
3.5.7.3 Feedwater supply
3.6 Electrical power isolation
3.7 Power failure protection
3.7.1 Design and construction
3.7.2 Hazard of overheating
3.8 Control equipment
3.9 Alarms
3.10 Visual display for boilers up to and including a power output of 500 kW
3.10.1 General
3.10.2 Fuel-fired boilers
3.10.3 Water level security
3.11 Visual display for boilers exceeding a power output of 500 kW
3.11.1 General
3.11.2 Fuel-fired boilers
3.11.3 Water level security
3.12 Combustion equipment for fuel-fired boilers
3.12.1 General
3.12.2 Alternative firing of main fuels
3.12.3 Alternative firing of main fuels, fluidized bed combustion boilers
3.12.4 Supplementary fuel firing
3.12.5 Combustion characteristics
3.12.6 Secure mounting
3.12.7 Adverse conditions
3.12.8 Visual flame-checking provisions
3.13 Multiple-burner installations
3.14 Air supply and control system
3.14.1 General
3.14.2 Air inlets
3.14.3 Proportioning
3.15 Ignition system
3.15.1 Start flame or pilot ignition
3.15.2 Ignition electrodes
3.15.3 High tension components
3.15.4 Location and fixing
3.15.5 Start gas rate
3.15.6 Main burner to start at a reduced rate
3.16 Main fuel firing rate
3.16.1 Low-fire rate operation
3.16.2 Low-fire interlock
3.16.3 Main flame turn down and modulation
3.16.3.1 Main flame turn down
3.16.3.2 Main flame modulation
3.16.4 Main flame firing rate
4 Additional requirements for oil-fired, gas-fired and solid-fuel-in-suspension-fired unattended and limited attendance boilers
4.1 Application
4.2 Operational requirements for oil, gas and solid-fuel-in-suspension management systems for boilers with a power output above 500 kW
4.2.1 Pre-start safety interlocks
4.2.2 Starting and operating sequence
4.2.3 Fault shutdown and lockout condition for other than forced circulation boilers
4.2.4 Fault complete shutdown and lockout condition for other than forced circulation boilers
4.2.5 Purging
4.2.6 Flame simulation
4.2.7 Fuel admission
4.2.8 Spark ignition period
4.2.9 Flame establishment period for spark ignition
4.2.10 Start flame proving
4.2.11 Main flame establishment period for start flame ignition
4.2.12 Ignition failure
4.2.13 Flame failure response
4.2.14 Controlled shutdown
4.3 Operational requirements for oil, gas and solid-fuel-in-suspension management systems for boilers up to and including a power output of 500 kW
4.3.1 Pre-start safety interlocks
4.3.2 Starting and operating sequence
4.3.3 Fault shutdown and lockout condition for other than forced circulation boilers
4.3.4 Flame simulation
4.3.5 Fuel admission
4.3.6 Spark ignition period
4.3.7 Flame establishment period for spark ignition
4.3.8 Start flame proving
4.3.9 Main flame establishment period for start flame ignition
4.3.10 Ignition failure
4.3.11 Flame failure response
4.3.12 Controlled shutdown
4.4 Specific requirements for oil-fired boilers
4.4.1 Oil fuel pretreatment
4.4.2 Gas pilot
4.4.3 Controls and safety devices
4.4.4 Fuel bypass valve
4.4.5 Steam air-atomized burners
4.4.6 Fuel oil installation
4.5 Specific requirements for gas-fired boilers
4.6 Specific requirements for solid-fuel-in-suspension-fired boilers
4.6.1 General
4.6.2 Controls and safety devices
4.6.3 Valve and piping arrangement
4.6.4 Fuel quality
5 Additional requirements for solid-fuel-fired (bed or grate) unattended or limited attendance boilers
5.1 Application
5.2 Operational requirements for solid fuel (bed or grate) management systems
5.2.1 Pre-start interlocks
5.2.2 Start-up
5.2.3 Controlled shutdown
5.2.4 Fault shutdown and lockout
5.2.5 Purging
5.3 Specific requirements for solid-fuel-fired (bed or grate) boilers
5.3.1 General
5.3.2 Fuel quality
5.3.3 Combustion equipment
5.3.4 Ignition of bed fuel
5.3.5 Controls and safety devices
5.3.6 Burn-back protection
5.3.7 Power failure protection
5.3.7.1 General
5.3.7.2 Draught safety device
5.3.8 Solid fuel and residue handling plant
6 Checking, testing and maintenance for unattended and limited attendance boilers
6.1 General
6.2 Organization and personnel
6.3 Responsibilities checking, testing and maintenance
6.3.1 Program and procedures
6.3.2 Periodic and yearly testing and maintenance
6.4 Checking and testing
6.4.1 Intermediate checking—Limited attendance operation
6.4.2 Daily checking—Unattended and limited attendance operation
6.4.3 Weekly checking—Unattended and limited attendance operation
6.4.4 Periodic testing
6.4.5 Changes to procedures
6.4.6 Log
6.5 Maintenance
6.5.1 Periodic maintenance
6.5.2 Yearly maintenance
6.5.3 Records
6.6 Retention of records
6.7 Maintenance contract
7 Attended boilers
7.1 General
7.2 Management system
7.3 Manual operation
7.4 Automatic operation
7.4.1 General
7.4.2 Automatic water level management
7.4.3 Alarms
7.4.4 Controls and boiler mountings
7.5 Low-water cut-out and alarm
7.6 Waterfeed control
7.6.1 General
7.6.2 Modulating water control
7.7 Operational supervision
7.8 Testing and checking programs
7.8.1 General
7.8.2 Checks
7.8.3 Log
7.9 Programmable logic controller (PLC) Management systems
7.10 Notices
8 Water level management and security for all types of boilers
8.1 Water level devices and interlocks
8.1.1 General
8.1.2 Electrical requirements
8.2 Water level indicators
8.2.1 Number and type
8.2.2 Length of gauge glass on boilers other than water-tube type
8.2.3 Glass diameter
8.2.4 Visibility and accessibility
8.2.5 Drains
8.2.6 Guards
8.2.7 Water level gauge connections and location
8.2.7.1 General
8.2.7.2 Hollow support connections
8.2.7.3 Electric boilers
8.2.7.4 Connections for two sets of gauges
8.2.7.5 Isolating valves
8.2.7.6 Vertical installation
8.2.7.7 Connections
8.2.8 Connecting pipes for water gauges
8.2.9 Safety devices
8.3 Feed systems
8.3.1 Design pressure
8.3.2 Design temperature
8.3.3 Feedwater arrangements
8.3.3.1 General
8.3.3.2 Specific requirements
8.3.3.3 Operating positions
9 Installation requirements of all types of boilers
9.1 Statutory requirements
9.1.1 Gas installations
9.1.2 Fuel oil installations
9.1.3 Solid fuel installations
9.1.4 Electrical installations
9.2 Housing, access and security
9.3 Feedwater supply
9.4 Water treatment
9.5 Blowdown
9.6 Flues and chimneys
9.7 Electrical equipment
9.7.1 Electrical requirements
9.7.2 Control cabinets
10 Marking and instructions for all types of boilers
10.1 Marking
10.2 Electrical data
10.3 Instructions
10.4 Language and units
10.5 Certificates
11 Energy input systems for all types of boilers
11.1 Combustion systems
11.1.1 Suitability
11.1.2 Combustion heat flux limitation
11.1.3 Automatic oil and gas firing equipment
11.1.4 Other oil, gas or solid-fuel-in-suspension firing equipment
11.1.5 Solid-fuel firing systems
11.1.5.1 General
11.1.5.2 Suitability
11.1.5.3 Solid-fuel firing systems
11.1.5.4 Power failure protection
11.1.5.5 Piping
11.2 Waste heat energy recovery system
11.2.1 Input control
11.2.2 Input location
11.3 Electric energy input systems
11.3.1 General
11.3.2 Electricity supply
11.3.3 Load adjustment
11.3.4 Electrodes, elements and internal parts
11.3.5 Pressure and temperature control
11.3.6 Access
12 Valves for all types of boilers
12.1 General
12.2 Size, number and location of safety valves for boilers
12.2.1 General
12.2.2 Discharge capacity
12.2.2.1 Unvented systems
12.2.2.2 Open-vented systems
12.2.2.3 Integral superheater discharge capacity
12.2.2.4 Independently-fired superheater discharge capacity
12.2.2.5 Reheater discharge capacity
12.2.2.6 Economizer discharge capacity
12.2.3 Accumulation
12.2.4 Reseating pressure
12.2.5 Valve settings
12.2.6 Connections to shell
12.2.7 Expansion joints
12.2.8 Pilot pipes
12.2.9 Safety valve discharge system
12.2.10 Discharge restriction
12.3 Blowdown valves
12.4 Main steam isolating valve
12.5 Main feedwater isolation valve
13 Integral and boiler pressure piping for all types of boilers
13.1 General
13.2 Water-heating boiler system design
13.2.1 General
13.2.2 Expansion vessels
13.2.2.1 General
13.2.2.2 Minimum requisite fittings
13.2.2.3 Gas safety valves
13.2.2.4 Low-water device
13.2.2.5 Boiler safety valves
13.2.3 Piping system
13.2.3.1 Design
13.2.3.2 Flow restriction
13.2.4 Make-up water systems
13.2.5 Energy input interlock
Appendix A
Appendix B
B1 General
B2 Organizational competencies
B3 Minimum competencies for personnel
B3.1 General
B3.2 Designer
B3.3 Commissioning body
B3.4 Servicing
B3.5 Commissioning and servicing of electric boilers
Appendix C
C1 General
C2 Type test
C3 Test procedure
C4 Acceptance criteria
Appendix D
Appendix E
Appendix F
Amendment control sheet
Cited references in this standard
Content history
[Current]
[Available Superseded]
[Superseded]
[Superseded]
AS 2593-2004 Rec:2016
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