Standard
Track updates
AS 2593:2021
[Current]Boilers — Safety management and supervision systems
Specifies the requirements for the operation of boilers and other devices including any connected economizer or superheater or deaerator. It includes the special features within the control, management and supervision systems, associated valves and fittings, housing, access and installation for those boilers and other devices operating in the unattended or attended modes. Details the checking, testing, supervision and maintenance requirements for each category of attendance to support continued safety.
Keywords: Boilers, Boiler management system, Attended boiler, Unattended boiler, Combustion equipment
Published: 19/03/2021
Pages: 75
Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
1 Scope and general
1.1 Scope
1.2 Application
1.3 Normative references
1.4 Terms and definitions
1.5 New designs, materials and construction methods
2 Design and construction for all types of boilers and other devices
2.1 General requirements
2.1.1 Basic design
2.1.2 Tube diameter
2.1.3 Water level indicators
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 Economizers
2.7 Superheaters
2.8 Deaerators
3 Boiler management system for unattended 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 fuel 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 tanks
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 control
3.5.3.2.3 Externally fitted water level device other than water level indicators
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 for coil-type forced circulation boilers
3.5.5 Water management systems for hot water boilers
3.5.5.1 General
3.5.5.2 Low-level water safety devices
3.5.5.3 Safety high limit temperature device
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 pumps for electric boilers
3.6 Electrical power isolation
3.7 Power failure and overheating protection
3.7.1 Design and construction
3.7.2 Hazard of overheating
3.8 Electrical 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 Heat effects to combustion equipment
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 Start flame or pilot ignition
3.14.3 Ignition electrodes
3.14.4 High voltage components
3.14.5 Location and fixing
3.14.6 Start gas rate
3.15 Main fuel firing rate
3.15.1 Low-fire rate operation
3.15.2 Low-fire interlock
3.15.3 Main flame turn down and modulation
3.15.3.1 Main gas flame turn down
3.15.3.2 Main oil flame turn down
3.15.3.3 Main flame modulation
3.15.4 Main flame firing rate
4 Additional requirements for oil-fired, gas-fired and solid-fuel-in-suspension-fired unattended 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 — Extraneous light
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 — Extraneous light
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 pre-treatment
4.4.2 Gas pilot
4.4.3 Controls and safety devices
4.4.4 Fuel bypass valve
4.4.5 Steam and 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 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 Inspection, checking, testing and maintenance for unattended boilers
6.1 General
6.2 Periodic checking, testing and maintenance personnel
6.3 Checking, testing and maintenance procedures
6.3.1 Program and procedures
6.4 Checking and testing
6.4.1 Additional checking and testing — Unattended operation
6.4.2 Daily checking and testing — Unattended operation
6.4.3 Weekly checking and testing — Unattended operation
6.4.4 Periodic checking, testing and maintenance — Unattended operation
6.4.5 Changes to procedures
6.4.6 Log — Daily and weekly checking — Unattended operation
6.4.7 Records — Periodic checking, testing and maintenance
6.5 Yearly and required maintenance — Unattended operation
6.5.1 Required maintenance
6.5.2 Yearly inspection, testing and maintenance
6.5.3 Records — Yearly and required maintenance
6.6 Retention of records
6.7 Maintenance checklist/instructions
7 Attended boilers
7.1 General
7.2 Electrical control equipment
7.3 Power failure and overheating protection
7.4 Management system
7.5 Manual operation
7.6 Automatic operation
7.6.1 General
7.6.2 Automatic water level management
7.6.3 Alarms
7.6.4 Controls and boiler mountings
7.7 Low-water cut-out and alarm
7.8 Water feed control
7.8.1 General
7.8.2 Modulating water control
7.9 Operational supervision
7.10 Testing and checking programs
7.10.1 General
7.10.2 Checks
7.10.3 Records — Checking Attended operation
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 water level indicators on boilers
8.2.3 Glass diameter
8.2.4 Drains
8.2.5 Guards
8.2.6 Water level indicator connections and location
8.2.6.1 General
8.2.6.2 Hollow support connections
8.2.6.3 Electric boilers
8.2.6.4 Connections for two sets of water level indicators
8.2.6.5 Isolating valves
8.2.6.6 Vertical installation
8.2.6.7 Connections
8.2.7 Connecting pipes for water level indicators
8.3 Feedwater 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 General 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
10 Marking, instructions and statements for all types of boilers
10.1 Marking
10.2 Electrical data
10.3 Instructions
10.4 Language and units
10.5 Boiler attendance-category statement
11 Energy input for all types of boilers
11.1 Combustion systems
11.1.1 Suitability
11.1.2 Emission requirements
11.1.3 Combustion heat flux limitation
11.1.4 Automatic oil and gas firing equipment
11.1.5 Other oil, gas or solid-fuel-in-suspension firing equipment
11.1.6 Solid-fuel firing systems
11.1.6.1 General
11.1.6.2 Suitability
11.1.6.3 Solid-fuel firing systems
11.1.6.4 Power failure and overheating protection
11.1.6.5 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 Valves and fittings for steam boilers
12.2.1 Minimum requisite fittings
12.2.2 Safety valves
12.2.3 Discharge capacity
12.2.3.1 Unvented systems
12.2.3.2 Open-vented systems
12.2.3.3 Integral superheater discharge capacity
12.2.3.4 Independently fired superheater discharge capacity
12.2.3.5 Reheater discharge capacity
12.2.3.6 Economizer discharge capacity
12.2.4 Accumulation
12.2.5 Reseating pressure
12.2.6 Valve settings
12.2.7 Connections to the boiler
12.2.8 Expansion joints
12.2.9 Pilot pipes
12.2.10 Safety valve discharge system
12.2.11 Discharge restriction
12.2.12 Blowdown valves
12.2.13 Main steam isolating valve
12.2.14 Main feedwater isolating valve
12.2.15 Isolating valves
12.3 Valves and fittings for hot water boilers
12.3.1 Minimum requisite fittings
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 Expansion vessel safety valves
13.2.2.4 Low-water device
13.2.2.5 Boiler safety valves fitted to expansion vessel
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
A.1 General
A.2 Type test
A.3 Test procedure
A.4 Acceptance criteria
Appendix B
Appendix C
Appendix D
Appendix E
Bibliography
Cited references in this standard
Content history
[Available Superseded]
[Available Superseded]
DR AS 2593:2019
AS 2593-2004 Rec:2016
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