Steam Boiler BG01 Compliance with Flomar

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BG01 Compliance
This is a guidance by M&M Training Services of the requirements of compliance to BG01 and
a recommended way forward for your company
To understand what the above implies, you must first understand several key issues;
Typical Arrangement Level
What is the current level of automation within the boiler house, please note if you have more
than one boiler, there may be a different level for each boiler. The arrangement for the lowest
level of automation will apply for the manning levels.
For example one boiler may have external Mobrey Level Controls whilst the other, perhaps a
more modern boiler would have high integrity level probes fitted in ‘pots’ mounted into the
top of the boiler shell.
Manning Levels
Once the automation of the boiler(s) and all other associated equipment is known, the
required manning levels can be set, i.e. for the highest level of automation, the minimum
amount of supervision can be put in place, typically with the boiler house being manned for a
period of up to 72 hours and for the lowest level of automation it may be that a boiler
operator has to be within the boiler house at all times.
Training
Boiler Operations – Review of Operator Competence – Requirements;
References;
A. Health and Safety at Work Act 1974
B. Provision and Use of Work Equipment Regulations 1998
C. Approved Code of Practise – L22 – Safe Use of Work Equipment
D. BG01 - Guidance on Safe Operation of Boilers – Edition 1 – October 2011
Introduction
Steam boiler operation is quite different, due to the hazardous nature of the boilers, from
general plant operation. Within the framework of Reference A. (Health and Safety at Work
Act) the following supplementary documents refer to the need for adequately trained
personnel when dealing with plant and equipment and steamplant inparticular; it may be that
after carrying out a technical boiler house risk assessment on any individual site further
bespoke training courses may be required.
In this example, little or no condensate was returned, posing a serious risk to the boiler from
hard water, for this reason a further course was inputted teaching oiler operatives how to take
water treatment samples and the understanding of the results.
It was also agreed that more emphasis should be given to the training on alarms, both critical
alarms and urgent alarms, boiler safe entry procedures etc. M&M Training put together a

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bespoke course for this client to teach both water treatment, alarms, panels and boiler house
safe entry procedures.
Each site needs to be evaluated for the needs for any extra training requirements that are felt
necessary, we are more than happy to design a bespoke course to match the sites
requirements.
Reference B; Reference Provision and use of Work Equipment Regulations 1998 and the
accompanying Approved Code of Practice
Reference C; ACOP L22 -Safe use of work equipment
Reference D; BG01 - Guidance on Safe Operation of Boilers – Edition 1 – October 2011
To ensure that all of the above is fully understood a technical boiler house risk assessment
needs to be carried out.
Risk Assessments
The Management of Health and Safety at Work Regulations 1999 (MHSWR) Regulation 3
requires the completion of a suitable and sufficient risk assessment of the work activity in
order to properly identify and adequately manage risks. This is of central importance. The risk
assessment is to identify sensible measures to control identified risks that may otherwise
result in injury or danger.
This Risk Assessment has to be produced to ensure that the boiler house is in line with the
guidance on Safe Operation of Boilers REF: BG01 and INDG436 - Safe Management of
Industrial Steam and Hot Water Boilers.
The above document applies to those industrial & commercial steam and hot water boiler
plant operating at a working pressure of between 0.5 and 32 bar gauge and working
temperature between 110⁰C to 400⁰C.
This risk assessment needs to look at all of the aspects laid down in BG01 and also the ‘wheel’
as shown in INDG 436.

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“The diagram on this page, taken from HSE INDG436 identifies that the achievement of safe
boiler plant arises from a combination of factors as identified by each of the spokes of the
diagram. All attributes must be properly managed.”
GETTING IT WRONG CAN HAVE SERIOUS CONSEQUENCES

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Our Analysis of Training Requirements
Each site will need to review and discuss the requirement for training and operation of plant.
It will probably identify that training and competency assessment is required at several levels.
Thelevels identified are nominated as;
 Boiler Manager
 Senior Boiler Operator
 Boiler Operator
The duties and responsibilities attributed to each grade are identified in Annex A together with
a description of the training and competency assessments for each grade.
In general, competency is gained by completion of;
 Appropriate training courses, including assessment tests/exams
 An appropriate period gaining experience, including completing a log book/task book
 A Practical Assessment by suitably qualified local staff or external personnel
Annex B gives a summary of the courses available from M&M.
At Annex C the requirements of Annex A and course availability of Annex B are brought
together in the proposed Training Matrix.
One point to note is that completion of the appropriate training alone is not sufficient for
determination of competence. It is the completion of Training, Experience and Assessment
thatis required.

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The key point that comes out of a review, is that safe operation of boiler plant does not
necessarily demand that each and every boiler operator is BOAS qualified but does demand
that each company has a robust process for training and certifying competence of boiler
operators.
Ultimately, could the company defend the position in Court? Indeed the BOAS (O)
qualification is regarded by some as equivalent to an A-Level in terms ofthe academic
requirements and not all operators would necessarily be able to cope with that level
academically, but they would be able to cope with the basic operation of boiler plant.
Proposalof Boiler Plant Training and Qualification Requirements
The revised proposal for manning on a boiler plant is that each site must have;
 Minimum 1 x BOAS (M) qualified Boiler Manager.
 Minimum 1 x BOAS (O) qualified Senior Boiler Operator
 As many as required Boiler Operators, CITB certified and tested for competency, but
not BOAS
It would be possible for one BOAS (M) manager to hold responsibility for more than one boiler
site.
Particularly in respect of the Senior Boiler Operators and Boiler Operators this revised
approach should;
 Provide a shorter and cheaper route to the development of Boiler Operators
 Prevent the demotivation of personnel who are pushed through for BOAS (O) but may
not be suited to that level
 Incentivise the BOAS (O) qualified operators to take some direct ownership of the
boiler plant

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Annexes;
A Boiler Operation – Manning Requirements
B M&M Training Services Limited – Steam Training Courses
C Boiler Plant Proposed Training Matrix
D Boiler Operator Training Record

Annex A – BoilerOperation– ManningRequirements
DS Smith
The tablesbelow summarisesthe Functions, Responsibilities andTrainingRequirementsassociatedwitheachtierof personnelengagedinBoilerPlant.Tables
are:
A1 BoilerPlant ManagerA2 SeniorBoiler OperatorA3 Boiler Operator
Table A1 BoilerPlantManager
Function Duties/Responsibilities Training Requirements
BoilerPlantManager Overall responsibilityforthe managementof the boiler plant
including:
 Carryingout dutiesof the useras outlinedinthe Pressure
SystemsSafety Regulations2000
 Ensuringsufficienttrainedandcompetentboileroperators
are available
 Manage SeniorBoilerOperatorandBoiler Operators
 Manage any environmentalissuesthatcouldimpacton the
business
 Weeklymonitoringandsigningof the boilerlogs, including
waterqualitytestingrecords.
 Maintainingadequate andcompleteboilerrecords,
including;
o WrittenScheme of Examination
o BoilerPlantRisk Assessment
o Recordsof maintenance and repair
o Ensure all mandatoryinspectionsare carriedout in
accordance withthe writtenscheme and
manufacturersrecommendationse.g.Boilerannual,
and 5 yearly, flue inspections,safetyvalves,pressure
vessels etc.
 SteamUtilisationCourse andCITBtest
 BoilerOperationsCourse andCITBtest
 BOAS(M) course and exam
 CompetencyconfirmationbySeniorcompany
manager(AreaManager),makinguse of
appropriate in-houseorexternal assistance

Table A2 – SeniorBoilerOperator
DS Smith
SeniorBoilerOperator SeniorBoilerOperatorfornominatedboilerplant. Duties include:
Operation
 Startingboilerfromcold
 Connectingboilertothe steam main
 Normal boileroperatingchecksand procedures
 Isolatingboilerfromthe steammain
 Lay-upboilerwhenoutof service
 FaultfindingtoIntermediate/Advanced level
 Monitorboiler/systemperformance forpotentialimpact on
site operation
Maintenance:
 MaintainingBoilerRecords,DailyandWeekly logs
 Carry out boilerchecks inline withsite proceduresbased on
BG01 Arrangement3 and logresults:
o EvaporationTest(weekly)
o Low level watercutout test(weekly)
o Gauge glassblow down(daily)
o Feedandboilerwatertest(daily)
 Adjustfeed/boilerwaterdosingbasedonwaterqualitytests
Training:
 TrainingandSupervisionof BoilerOperatorsfor the
achievement/maintenance of appropriate boiler operating
standards
 Carry out the competencyAssessmentof Boiler Operators
 SteamUtilisationEquipmentCourse andCITB test
 Alarms,FaultFinding,watertreatmentand testing
course
 6months/ 100 hoursdocumented experience
 CompletedBoilerOperator‘Task Book’
 BOAS(O) course and exam
 Practical assessmentconductedbyBOAS examiner
and SeniorBoilerOperator,confirmedby Boiler
Manager

DS Smith
BoilerOperator BoilerOperatorfornominatedboilerplant. Dutiesinclude:
Operation
 Startingboilerfromcold
 Connectingboilertothe steam main
 Normal boileroperatingchecksand procedures
 Isolatingboilerfromthe steam main
 FaultfindingtoBasic/Intermediate level
Maintenance
 MaintainingBoilerRecords,DailyandWeekly logs
 Carry out boilerchecksinline withsite proceduresbased on
BG01 Arrangement3 and logresults:
o EvaporationTest(weekly)
o Low level watercutouttest(weekly)
o Gauge glassblow down(daily)
o Feedandboilerwatertest(daily)
 Adjustfeed/boilerwaterdosingbasedonwaterquality tests
 Reportany unusual circumstancestothe seniorboiler
operator
Training
 Trainingof FirstResponse Call Outpersonnelonthe
nominatedboiler(s)
Note:Priorto the confirmationof CompetencyAssessmenta Boiler
Operatormay only carry out the above tasksunderthe supervision
of a SeniorBoilerOperator.
 SteamUtilisationCourse andCITBtest
 Alarms,FaultFinding,watertreatmentand testing
course
 3 months/ 50 hoursdocumented experience
 CompletedBoilerOperator‘Task Book’
 Practical assessmentconductedbySenior Boiler
Operator,confirmedbyBOAS(M) Boiler Manager

DS Smith
M&M Training Services
Training Brochure 2015/16 Steam & Process Training Courses

DS Smith
Introduction
For over 30 years M&M Training Services have been providing training in the Steam and Process
Market. We have our own purpose built training centre in Leicestershire.
Training Centre
Glass Working Models
We can also provide training at our clients’ facility.
We are a member of the CEA, and act on its Council.
We are part of the BOAS Working Group.
We are an approved training centre for the CEA.
We also have certification with the Construction Industry Board (CITB), now calledC-Skills.

DS Smith
Courses Available
Course Type External Accreditation Course Duration
A Steam Awareness Course 1 day
B Steam Utilisation Course CITB (C-Skills) 1 day
C Boiler Operator Course CITB (C-Skills) 1 day
D
Boiler Alarms Response and Fault Finding
plus Water Treatment and Testing
1 day
E BOAS Cat 2 Steam Boiler Course Gastec 4 days
F BOAS Cat 1 Hot Water Boiler Course Gastec 4 days
G Steam Equipment Maintenance Course 1 day
H Boiler House Risk Assessment
1 day on site
2 days off site
J Steam Audits TBA
K Refresher Courses CITB (C-Skills) / Gastec 1 or 2 days
L Bespoke Courses TBA
Industries That Should Attend This Formal Training
 Foodand beverage
 Laundries
 Corrugatingplants
 Abattoirs
 Hospitals
 Publicworks departments
 Petrochemical plants
 Sewage treatment plants
 Facilitiesmanagementcompanies
 Motor manufacturers
 Tyre manufacturers
 Contractors
 Projectengineers
 Equipmentmanufacturersinvolvedin steam
All companies thathave a steamboileronsite mustgive adequate trainingonthe boilerplant.
Most accidentsand boilerfailuresare attributedtooperatorerror.
Most insurance companiesinsistonformal documented training.

DS Smith
Please findbelow a resume of the course contents;
Steam Awareness Course
SeminarLength: 1 day
Maximumnumberof delegatesatthe client’ssite: 10 persons
Who should attend?
Thiscourse is intendedforpersonnel thatare new tosteamand boilersystemsORfor plantoperators,
productionpersonnelandsite staff whomaybe involvedinthe isolation andreinstatementof the
steamsystemtoareas of the plantandmachineryIt givesabasic insighttothe boilerhouse and
associatedequipment,basicplantawarenessandcurrentlegislation.
Aims
To ensure thatall personnel involvedwithsteamequipmentunderstandthe principlesandeffects of
steam, how andwhere steamisformed, the effectsof steamandcondensate withinthe systemandthe
safety implications.
Contents
 Boilerhouse equipment&layout
 Boiler
 Hot well &feed pump
 Water treatmentsystem
 How steamisformed
 Steamtables
 Saturation curve
 Pressure &temperature relationship
 Basic steamandcondensate loop
 Steamdistribution&headers
 Pressure reduction
 Benefitsof condensaterecovery
 Condensate recovery methods
 Safety
 Boilermanninglevels(BG01guidelines)
 Isolationof asteam system
 Introducingsteamintoasystem
 Health& safetyresponsibilitiesof employer andemployee

DS Smith
Steam Utilisation Course
CITB(Construction IndustriesTraining Board) (C-Skills)Accredited
Who should attend?
Thiscourse is intendedforall personnel thatare involvedwithsteamplant andare responsibleormay
become involvedwiththe installationormaintenance of steamequipment.The course coversthe
relevantmandatoryregulationsandHealthandSafetyguidelines.
Aims
To ensure thatall personnel involvedwithsteamequipmentunderstandthe principlesof steamand
are able torecognise how steamequipmentshould be sized, installedandchecked togive maximum
efficiencyandoperate safely.
The course coversall manufacturers’equipmentandistotallyunbiasedtotypesof equipmentsupplied.
Delegatescanbe frommechanical or electrical backgrounds.
The delegatesare giventhe opportunitytotake a C.I.T.B.examinationwhichisarecognised
qualificationandisvalidfor5years. If yourengineersdorequire the CITB Test,please askthemtobring
a passportsize photographandtheirNational Insurance Number
Content
 The basic principlesinraisingsteam
 Healthand Safety regulations
 Pressure SafetyStandards Regulations
 Steamtrap operationand types
 Installationand sizingof steamandcondensate mains
 Operationof pressure reducing valves
 Maintenance safety procedures
 Practical demonstrationof traptypesand checking
 Basic principlesof goodworking practice
 CITB Test

DS Smith
Boiler Operators Course
CITB(Construction IndustriesTraining Board) (C-Skills) Accredited
Who should attend?
Thiscourse isintended forall personnelinvolved withthe running,managementandmaintenance of
steamand or hot waterboilerplant. The course covers all the mandatory requirements aroundthe
boiler.
Aims
To give a goodunderstandingof the operationof steamandhotwaterplantand to ensure operators
are aware of the mandatory requirementssurroundingthe operationof asteamboilerincludingBG01
guidelines.
The delegatesare giventhe opportunitytotake a C.I.T.B.examinationwhichisa recognised
qualificationandisvalidfor5years. If yourengineersdorequire the CITB Test,please askthemtobring
a passportsize photographandtheirNational Insurance Number.
Content
 The basic make-upof the steam boiler
 Operationof gasand oil burners
 Water treatment
 Boileroperation
 Mandatory & BG01 guidelines
 Boilerlog
 TDS and blowdown operation
 Safe isolationof the boilerandboiler lay-up
 Annual checks
 Faultfinding
 Practical test
 CITB test

DS Smith
Panel Alarms, Response and Fault Finding plus Water Treatment and Testing Course
Who should attend?
Thiscourse is intendedforpersonnel thatare new tosteamand boilersystemsORfor plantoperators
whoneedto respondtoboileralarms, itgivesabasicinsighttothe boilerhouseoperationandboiler
alarmconditions.
Boileroperatorswhoaspart of the operationcarryout feedandboilerwaterchecks.
Aims
To ensure thatall personnel involvedwithrespondingtoboileralarmconditionsunderstand the safety
implicationswhen enteringaboilerhouse andthe processtofollow inorderthe make the boilerhouse
safe.Carry outfaultfindingprocedures,resolvingthe issuesandre-instatingtheboilertoensure that
all personnel thatcarryout watertreatmenttestingunderstandthe science andprocessestomaintain
the correct waterquality.
Contents
Boiler Panels
 Remote on site
 Remote off site
 Critical alarms
 Secondary alarms
 Operatorresponse
 Enteringa boilerhouse safely
 Faultfindingand diagnostics
Water Quality Testing
 Raw water
 Treatedwater
 Hotwell
 Feedwater
 Boilerwater
 Documentation
 Qualitytestprocedures
 Results analysis
 Carryingout adjustments

DS Smith
Boiler Operation Accreditation Scheme (BOAS) Cat 2 Steam Boilers
Seminar Length: 4 days
Minimumcharge for Gastecat a client’s site: 4 persons
MaximumNumbersata client’s site: 8 persons
What isBOAS?
The BoilerOperationAccreditationScheme(BOAS)providesnationalaccreditationfor industrial boiler
operatorsandboilerplantmanagers,a course recommendedbyBG01 ‘Guidance onthe Safe Operation
of Boilers’.
M&M TrainingServices isalicensed andapproved BOAStrainingprovider. The BOAScourse provides
trainingtothe BOASsyllabusandincludesthe writtenexamination.
Candidates are alsointerviewed byanaccredited assessorduringthe course.
Successful candidates mayuse the designatorletters"CertIBO"(CertifiedIndustrial BoilerOperator) or
"DipBOM" (DiplomainBoilerPlantOperationManagement).Candidatesfromboth awardcategories
take the same course andwrittenpapers.Interviewsare specifictoeachaward. The awards are valid
for5 years, afterwhicharefreshercourse becomes necessary.
Who WillBenefit?
Thiscourse is suitable for:
 Boileroperatorswith hands-onexperience (evidence mustbe provided)
 Boilerplantmanagersandsupervisors(nohands-onexperiencerequired)
Those newto the boilerhouse wishingtohave introductoryboilertrainingshouldconsider ourBoiler
Operators course.
Objectives
 To train andprepare candidatesforthe BOAS qualification
 To promote safetyandenergyefficiencyinthe boilerhouse withdue regard toenvironmental
aspectsand legal requirements
Delegates Will LearnAbout
 Heat andheat transfer
 Boilersand auxiliaries
 Feedwater
 Draught and combustion
 Control and instrumentation
 Fuels
 Safetyand legal
 Energy efficiency
 Environmental
 Operation

DS Smith
BOAS (O) Cat2 - Full Assessmentof the Competence of BoilerOperatives Pre-requisites
Thisassessmentof competence requires noformal qualifications,althoughapplicants are expectedto
be in currentemploymentwithin(orhave readyaccessto) a boilerhouse.
Candidates will be expected topresenta record of theirtraining, andcandidates are warned that
withoutsome recentup-skillingthe assessmentmaybe difficulttopass.
The Assessment Process
The assessmentisinthree distinct sections;
1. Five writtenpaperscontainingamixture of textandmultiplechoice questionsonall aspectsof
boilerhouse operation.Thiscoversonlythe principlesandisapplicable toall 4categories. This
can be sat at Gastec at CRE Ltd Cheltenham, atanyapprovedtrainingcentre;orat the client’s
site.
The followingtestpapersare closed book;
 Paper1 - Boiler, HeatandHeat transferconcepts,Draft& Combustion
 Paper2 - Feedwater,control and instrumentation
 Paper3 - Safetyand Legal
 Paper4 - EnergyEfficiencyand Environment
 Paper5 - Operationand fuels
2. Completion of anevidencepack (work recordorlogbook) atthe operative’s boilerhouse.
Thiswill include compilation of:-
 Schematicof boilerplantandsteam range
 All of the otherdetailsof the plantdescribed above
 Detailsof the boilers themselves
 Outline of routine actionscarriedoutbythe candidate
 Detailsof all non-routine actionscarriedoutbythe candidate
3. An onsite assessmentbyaBOASassessor.Thiswill includereview of the writtenpapers, the
evidence packanda spotauditto verifythe candidate’spractical expertise.
4. The pass mark is70%, exceptonthe safetypaperwhere the markis100%. For the paper
candidates willbe expected toachieveatleast80% inthe writtenalthoughthey will be allowed
to revisitdeficientanswersduringthe onsite assessment.
Assessors
All BOASassessorswill have suitableboilerhouse experience.
CV’sof staff will be approvedbythe CEA.

Steam Equipment Maintenance Course
Who should attend?
Thiscourse is intendedforall personnel thatare involvedwithsteamplantandare responsibleormay
become involved withthe installation ormaintenance of steamequipment. Italsoaimstotrain
personnel onthe symptomsinvolvedwith the failure ofequipment.
Aims
To ensure thatall personnel involvedwithsteamequipmentunderstandthe principlesandeffects of
steamon the equipmentused.Includingfaultfindingandrepairs.
Contents
 Pipe,Flangesand gaskets
 Steamtrap maintenance
 Pressure reducingvalves maintenance
 Maintenance safety procedures
 Bellowssealed valves
 Piston valves
 Parallel slidevalves
 Steamtrap testing
 Pressure relief valves
 Strainers
 Condensate recovery units
 Pumpingtraps

Risk Assessment In line with BG01 Guidance on Safe Operation of Boilers
Enersol FlomarandM&M TrainingServicesLtdare able to offeranindependentriskassessment of your
BoilerHouse.We have professional andcompetentengineerswhoare able tocarry out theRisk
Assessmentandprovide youwithawrittenreport.Shouldthere be anyissueswithyour sitemeeting
the currentguidelines, we are alsoinaposition toeither:offeryouthe equipmentneeded,ortocarry
out a full mechanical andelectricalturnkeyproject.
Legal Responsibilities –RiskAssessments – ForNew andExistingSites
Regulation3of Managementof HealthandSafetyat workRegulationsrequiresthata‘suitable and
sufficient’riskassessmentbe carriedoutbefore the workactivity commences.Itspurpose isto
determine whetheranyrisksare presentand,if theyare not adequatelymanaged,what furthercontrol
measuresare required.The significantfindingsof the riskassessmentmustbe recordedwhere there
are 5 or more employees.
The control measures musthave the primary aimof eliminatingthe risks. Whereelimination isnot
possible,the control measuresshouldaimtoreduce the riskstoa level aslow asis reasonablypractical
(ALARP).Regulation4andSchedule 1 of MHSWR sets out the principlesofprevention.
The responsibilityforthe riskassessmentlieswiththe employeralthoughhe maydothisusing inputor
assistance fromvarious sources suchasboilermanufacturers andcontrol systemexperts, orhave the
entire risk assessmentcarriedoutonhisbehalf bysomeone competenttodoso.
For A Boiler,the RiskAssessmentShouldConsiderIssuesSuch As
The likelihoodandseverityof injuries from;
 Burns from:hot water,steam,burnersand flues
 Electricshock
 Fuel escape
 Fire
 Asphyxiation,andtoxiceffectsfromcombustion products
The locationof the boilerwithrespect to;
 Proximitytoindustrialpremises/workers
 Proximitytothe publicespeciallyvulnerable populations - suchasin:nurseries,schools,
hospitals,care homesetc
 The potential impactonneighbouringsitesdue toan incident
 Capabilityof safety-relatedsystems
 Level of supervision
 The positioningof alarmsandthe associatedresponse times
 The presence of otherdangerous materials
 The adequacyof boilerhouse ventilationandflue integrity
 Environmental effects,e.g.noise, pollution
 Effectof chemicalsonworkers,environmentandothers,e.g.watertreatment chemicals

Operational Risks:
 Mechanical or waterdamage to plantor equipment
 Water-side explosiondue tocatastrophicfailureof the pressure envelope
 Combustionexplosioncausedbyunspent fuel
Since riskassessmentsmustassessthe existingcontrol measures,theyshouldalso considerinformation
regarding:
 Manninglevels
 Type and reliabilityof controlsandthe integrityof safety-relatedsystems
 Additional controlsforremote orunsupervisedboiler operation
Riskassessments mustbe reviewedperiodically andwhenthereisasignificantchange e.g. asystem
variation, change inoperatingparameters ormanninglevelsetc. The outcome of any reviewsshould
alsobe recorded.
As an example,anownermovingfromamannedboilertoan unmannedboilershould,asa firststep,
reviewthe boilerdesignandthe current/recentriskassessmentto take accountof the plannedchange
inmanninglevels.The resultsof the riskassessmentwillbe usedtodetermineanymeasures necessary
to ensure thatthe boilerremainssafe touse andoperate. Suchmeasures mayinclude:
 The properformulationandcorrectapplicationof all modificationsandinstallationstoensure
theyhave sufficientsafetyintegritytoadequatelycontrol the riskof adangerousoccurrence
 Amendmentof procedureswhere appropriate toensure the plantcontinuestobe operated
safely
 All personnel on-site&off-siteandsurroundingpropertyremain safe

Steam & Condensate Audits
SteamGeneration Efficiency
Withenergy prices increasing, improvingthe boilerandplantefficiency isvitaltoreducingenergy,
waterand chemical costs.
Enersol Flomarisable to provide aconsultative service backedupbybeingable tofully turnkeyproject
manage any works required toimprove the boilerandplantefficiency shoulditbe required.
Our experienceallowsustomaximiseyourefficiencies inamannerthatallowsthe clienttochoose a
stepby stepprogramme basedon(where possible) ROI(returnof investment).
The firststepin improvingyourefficiencyistoundertake aSteamand Condensate System Audit.
Steamand Condensate SystemAudit
The audit whichiscustomisedforeachindividual clientinvestigatesareasfromthe followingcriteria;
Catalogue key equipment
 Designof distributionsystemandcondensatereturnsystem(steamtraps,drop outpoints,pipe
sizingetc)
Steamtrap survey
 Thiswill showleakingorblockedtraps.Lossesshall be showninkilogramsperhouralongwith
cost
EstablishFlue Loss
 Considereconomisers
EstablishBlowdown Loss
 Considerautomatedblow down
EstablishTDS Loss
 ConsiderautomatedTDS control
EstablishHotwell /FeedWaterTemperature
 Considerationgiventoraisinghotwell temperatureviasteaminjectionandorTDSheat
recovery.Othermethodsare alsoconsidereddependentuponthe client’sinstallation
Establishradiatedheatloss(boilerends,pipe work, valves)
 Considerlaggingoptions
Establishburnerefficiency
 ConsiderReplacingmechanical orlinkedburnercontrolswithmodernindependentmotor-
drivenfuel air-mixture controls
 Considerfixedspeedfansandmotors withvariable speed units
 Considerreducingburnersize onaboilerthatconsistentlyrunsbelow optimum load
 Considersequencingmultiple boilersusingaboilermanagementsystemcontrolledbyaplant
managementprogramme

EstablishProductionSteamLoad Requirements
 Consideraloadbalancingsystemwhichwill determine whenanadditionalboilershouldbe
broughtonline aswell aswhichunitswill be mostefficientatgiven total load
EstablishCurrentOperating Parameters
 ConsiderOperating“NoCost”OperatingImprovements
Healthand safety recommendations
 ConsiderationgiventoINDG346, BG01, PM60 and Safed regulations
Report Deliverables
A reportwill be issuedtothe clientanddependentuponthe level carriedoutto - will deliverthe
followinginformation;
 Inventoryof equipment
 Currentboilerefficiency
 Recommendationof areasof improvements
 Cost of improvement
 Returnof investment(where applicable)
 Efficiency% improvement
 Overall efficiencyafterrecommendationshasbeencarried out.
Benefits of SteamandCondensate SystemAudit
 Energysavings
 Qualityimprovements
 Productivityimprovements
 Reduced maintenance
 Fewerbreakdowns
 ImprovedHealthand safety
 A focusedroute tocost reductions

Annex C– Company BoilerPlantproposed Training Matrix Table C1 Training Matrix
Grade Courses Practical Experience
Final
Assessment
Re-
Qualification
Boiler Manager  SteamAwareness
Course (A)
 SteamUtilisation
Course (B)
 BoilerOperatorCourse
(C)
 BoilerAlarms Response
and FaultFinding,plus
Water Treatmentand
Testing(D)
 BOASCat 2 Steam
BoilerCourse (E)
No specificexperience required,but
the candidate will needto
demonstrate anunderstandingof
the principlesof operation;and
provide evidence priorto the BOAS
course that theyhave witnessed/
signedoff boilerhouseprocedures
as per Annex D
BOAS(M)
examsand
Oral
Assessment
BOAS(M) re-
qualifyat5 year
intervals
Senior Boiler
Operator
(SBO)
 SteamAwareness
Course (A)
Course (B)
(C)
 BOASCat 2 Steam
BoilerCourse (E)
6 monthsor 100 hours.
Completionof BoilerOperationsLog
Book/ Task Book / CheckSheet
BOAS(O)
Examsand
Oral
Assessments
BOAS(O) re-
qualifyat5 year
intervals
Boiler Operator  SteamAwareness
Course (A)
Course (B)
(C)
 BoilerAlarmsResponse
and FaultFinding,plus
Water Treatmentand
Testing(D)
3 monthsor 50 hours.
Completionof BoilerOperations
Task Book/ CheckSheet
CITB (C-
Skills) testat
Boiler
Courses.
Oral /
Practical
assessment
by SBO.
CITB re-qualify
at 5 year
intervals.
Local
reassessmentby
SBO whenCITB
isin date.

TrainingCycle
The basic trainingcycle forboilerplantoperatorsandassociatedpositionisasthe drawingFigure C1below.The particularrequirementsforeachgrade of
personare identifiedinTable C1above.
Figure C1 Training Cycle
Formal Training
Courses
Practical experience
Assessment Qualified
Log Book/Task Book
Re-qualification

Annex D- BoilerOperator Training Record
ThisTrainingrecordforms the basisof a Log Book/Task Bookfor completionbyBoilerOperatorsand
SeniorBoilerOperatorstodemonstrate theircompetence inBoilerOperations.
Operator’sName
Assessor’ Name
DEMONSTRATE HOW TO CARRY OUT THE FOLLOWING TASKS
Ref Task DATE Sign Off By
1 Identify the boiler fittings & mountings
2 Starting a boiler from cold
3 Starting a warmboiler
4 Connecting a boiler to the steam main
5 Shutting down a boiler
6 Crowning off a boiler
7 Blowing down the boiler in manual control
8 How to over-ride the automatic blow down valve
9 Blowing down the gauge glasses
10 Carry out an evaporation test
11 Checking the burner flame detector
12 Reading the TDS value
13 Demonstrate how to use the sample cooler
14 Operate the automatic valves from the control panel
15 Responding to alarms
16 Accepting the boiler panel alarm
17 Understanding the boiler panel alarms
18 Your action in the event of a fire in the boiler house
19 How to isolate the fuel supplies
20 Isolating the electricalsupplies to the boiler
21 Filling out the boiler house log sheets
22 Demonstrate how to put the economiser on line
23 Demonstrate how to bypass the economiser
24 Demonstrate how to take economiser readings
25 Checking the hot well level
26 Draining down the hot well
27 Checking the hot well temperature
28 Checking the feed pumps
29 Starting and stopping a feed pump
30 Checking the chemical tanks & pumps
31 General house-keeping tasks
32 Checking the boiler house traps
33 Reading the steam meter total & rate
34 Reading the gas meter
35 Reading the make-up water meter
36 Drawing and test off raw water to boiler plant
37 Drawoff and test feed water to boiler
38 Drawoff and test boiler water
39 Adjust water treatment to achieve correct waterquality

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