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  • AS 2593-2001

    Superseded A superseded Standard is one, which is fully replaced by another Standard, which is a new edition of the same Standard.
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    Boilers - Unattended and limited attendance

    Available format(s):  Hardcopy, PDF 1 User, PDF 3 Users, PDF 5 Users, PDF 9 Users

    Superseded date:  30-06-2017

    Language(s): 

    Published date:  13-07-2001

    Publisher:  Standards Australia

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    Table of Contents - (Show below) - (Hide below)

    1 - AS 2593-2001 BOILERS-UNATTENDED AND LIMITED ATTENDANCE
    4 - PREFACE
    5 - CONTENTS
    7 - SECTION 1 SCOPE AND GENERAL
    7 - 1.1 SCOPE
    8 - 1.2 REFERENCED DOCUMENTS
    8 - 1.3 DEFINITIONS
    8 - 1.3.1 Acceptable, acceptance, accepted
    8 - 1.3.2 Bed
    8 - 1.3.3 Bed warm-up gas
    8 - 1.3.4 Boiler attendant
    8 - 1.3.5 Boilers
    8 - 1.3.6 Chimney
    8 - 1.3.7 Energy input management system
    9 - 1.3.8 Flue
    9 - 1.3.9 Maintenance contractor
    9 - 1.3.10 Proved
    9 - 1.3.11 Purging
    9 - 1.3.12 Trained person
    9 - 1.4 NEW DESIGNS, MATERIALS AND CONSTRUCTION METHODS
    11 - SECTION 2 DESIGN AND CONSTRUCTION
    11 - 2.1 GENERAL REQUIREMENTS
    11 - 2.1.1 Basic design
    11 - 2.1.2 Tube diameter
    11 - 2.1.3 Water gauges
    11 - 2.2 STEAM BOILERS (OTHER THAN ELECTRIC BOILERS)
    11 - 2.2.1 General
    11 - 2.2.2 Water-tube steam boilers
    11 - 2.2.3 Steam boilers other than water-tube or electric boilers
    12 - 2.3 HOT WATER BOILERS
    12 - 2.3.1 General
    12 - 2.3.2 Hot water systems
    12 - 2.4 WASTE HEAT BOILERS
    13 - 2.5 ELECTRIC BOILERS
    13 - 2.6 SUPERHEATERS
    14 - SECTION 3 BOILER MANAGEMENT SYSTEM
    14 - 3.1 GENERAL
    14 - 3.2 FAIL-SAFE TECHNIQUES
    14 - 3.3 TEMPERATURE SUITABILITY OF COMPONENTS
    14 - 3.4 COMBUSTION MANAGEMENT
    14 - 3.4.1 General
    15 - 3.4.2 Power-operated valves
    15 - 3.4.3 Flame detectors
    15 - 3.5 WATER MANAGEMENT SYSTEM
    15 - 3.5.1 For steam boilers other than coil- type forced circulation boilers and electric boilers
    16 - 3.5.2 Water management systems for coil- type forced circulation boilers
    17 - 3.5.3 Water management systems for hot water boilers
    17 - 3.5.4 Water management systems for waste heat boilers
    17 - 3.5.5 Water management systems for electric boilers
    19 - 3.6 ELECTRICAL POWER ISOLATION
    20 - 3.7 POWER FAILURE PROTECTION
    20 - 3.7.1 Design and construction
    20 - 3.7.2 Hazard of overheating
    20 - 3.8 CONTROL EQUIPMENT
    20 - 3.9 ALARMS
    20 - 3.10 VISUAL DISPLAY (FOR BOILERS EXCEEDING A POWER OUTPUT OF 500 kW)
    20 - 3.10.1 General
    20 - 3.10.2 Fuel-fired boilers
    21 - 3.10.3 Water level security
    21 - 3.11 COMBUSTION EQUIPMENT FOR FUEL-FIRED BOILERS
    21 - 3.11.1 General
    22 - 3.11.2 Alternative firing of main fuels
    22 - 3.11.3 Alternative firing of main fuels, fluidized bed combustion boilers
    22 - 3.11.4 Supplementary fuel firing
    23 - 3.11.5 Combustion characteristics
    23 - 3.11.6 Secure mounting
    23 - 3.11.7 Adverse conditions
    24 - 3.11.8 Visual flame-checking provisions
    24 - 3.12 MULTIPLE-BURNER INSTALLATIONS
    24 - 3.13 AIR SUPPLY AND CONTROL SYSTEM
    24 - 3.13.1 General
    24 - 3.13.2 Air inlets
    24 - 3.13.3 Proportioning
    24 - 3.14 IGNITION SYSTEM
    24 - 3.14.1 Start flame or pilot ignition
    24 - 3.14.2 Ignition electrodes
    24 - 3.14.3 High tension components
    24 - 3.14.4 Location and fixing
    25 - 3.14.5 Start gas rate
    25 - 3.14.6 Main burner to start at a reduced rate
    25 - 3.15 MAIN FUEL FIRING RATE
    25 - 3.15.1 Low-fire rate operation
    26 - 3.15.2 Low-fire interlock
    26 - 3.15.3 Main flame turn down and modulation
    26 - 3.15.4 Main flame firing rate
    27 - SECTION 4 ADDITIONAL REQUIREMENTS FOR OIL-FIRED, GAS-FIRED AND SOLID-FUEL-IN-SUSPENSION-FIRED BOILERS
    27 - 4.1 APPLICATION
    27 - 4.2 OPERATIONAL REQUIREMENTS FOR OIL, GAS AND SOLID-FUEL-IN-SUSPENSION MANAGEMENT SYSTEMS
    27 - 4.2.1 Pre-start safety interlocks
    27 - 4.2.2 Starting and operating sequence
    28 - 4.2.3 Fault shutdown condition for other than forced circulation boilers
    28 - 4.2.4 Fault shutdown sequence for a forced circulation boiler
    29 - 4.2.5 Purging
    29 - 4.2.6 Flame simulation
    29 - 4.2.7 Fuel admission
    30 - 4.2.8 Spark ignition period
    30 - 4.2.9 Flame establishment period for spark ignition
    30 - 4.2.10 Start flame proving
    30 - 4.2.11 Main flame establishment period for start flame ignition
    30 - 4.2.12 Ignition failure
    30 - 4.2.13 Flame failure response
    30 - 4.2.14 Controlled shutdown
    31 - 4.3 SPECIFIC REQUIREMENTS FOR OIL-FIRED BOILERS
    31 - 4.3.1 Oil fuel pretreatment
    31 - 4.3.2 Gas pilot
    31 - 4.3.3 Controls and safety devices
    31 - 4.3.4 Fuel bypass valve
    31 - 4.3.5 Steam-atomized burners
    31 - 4.3.6 Fuel oil installation
    31 - 4.4 SPECIFIC REQUIREMENTS FOR GAS-FIRED BOILERS
    32 - 4.5 SPECIFIC REQUIREMENTS FOR SOLID-FUEL-IN-SUSPENSION-FIRED BOILERS
    32 - 4.5.1 General
    32 - 4.5.2 Controls and safety devices
    32 - 4.5.3 Valve and piping arrangement
    32 - 4.5.4 Fuel quality
    33 - SECTION 5 ADDITIONAL REQUIREMENTS FOR SOLID-FUEL-FIRED (BED OR GRATE) BOILERS
    33 - 5.1 APPLICATION
    33 - 5.2 OPERATIONAL REQUIREMENTS FOR SOLID FUEL (BED OR GRATE) MANAGEMENT SYSTEMS
    33 - 5.2.1 Pre-start interlocks
    33 - 5.2.2 Start-up
    33 - 5.2.3 Controlled shutdown
    34 - 5.2.4 Fault shutdown
    34 - 5.2.5 Purging
    34 - 5.3 SPECIFIC REQUIREMENTS FOR SOLID-FUEL-FIRED (BED OR GRATE) BOILERS
    34 - 5.3.1 General
    34 - 5.3.2 Fuel quality
    34 - 5.3.3 Combustion equipment
    34 - 5.3.4 Ignition of bed fuel
    34 - 5.3.5 Controls and safety devices
    35 - 5.3.6 Burn-back protection
    35 - 5.3.7 Power failure protection
    35 - 5.3.8 Solid fuel and residue handling plant
    36 - SECTION 6 INSTALLATION
    36 - 6.1 STATUTORY REQUIREMENTS
    36 - 6.1.1 Gas installations
    36 - 6.1.2 Fuel oil installations
    36 - 6.1.3 Solid fuel installations
    36 - 6.1.4 Electrical installations
    36 - 6.2 HOUSING, ACCESS AND SECURITY
    36 - 6.3 FEEDWATER SUPPLY
    36 - 6.4 WATER TREATMENT
    36 - 6.5 BLOWDOWN
    36 - 6.6 FLUES AND CHIMNEYS
    37 - SECTION 7 MARKING AND INSTRUCTIONS
    37 - 7.1 MARKING
    37 - 7.2 ELECTRICAL DATA
    37 - 7.3 INSTRUCTIONS
    37 - 7.4 LANGUAGE AND UNITS
    37 - 7.5 CERTIFICATES
    38 - SECTION 8 CHECKING, TESTING AND MAINTENANCE
    38 - 8.1 GENERAL
    38 - 8.2 ORGANIZATION AND PERSONNEL
    38 - 8.3 RESPONSIBILITIES CHECKING, TESTING AND MAINTENANCE
    38 - 8.3.1 Program and procedures
    38 - 8.3.2 Periodic and yearly testing and maintenance
    38 - 8.4 CHECKING AND TESTING
    38 - 8.4.1 Limited attendance supervision
    39 - 8.4.2 Daily checking
    39 - 8.4.3 Weekly checking
    39 - 8.4.4 Periodic testing
    40 - 8.4.5 Changes to procedures
    40 - 8.4.6 Recording
    40 - 8.5 MAINTENANCE
    40 - 8.5.1 Periodic maintenance
    41 - 8.5.2 Yearly maintenance
    41 - 8.5.3 Records
    41 - 8.6 RETENTION OF RECORDS
    41 - 8.7 MAINTENANCE CONTRACT
    41 - 8.7.1 Scope of contract
    42 - APPENDIX A - LIST OF REFERENCED DOCUMENTS
    43 - APPENDIX B - ACCEPTABLE CRITERIA FOR ORGANIZATIONS AND PERSONNEL UNDERTAKING BOILER CONTROL DESIGN, TESTING AND SERVICING
    43 - B1 GENERAL
    43 - B2 ORGANIZATIONAL COMPETENCIES
    43 - B3 MINIMUM COMPETENCIES FOR PERSONNEL
    43 - B3.1 General
    44 - B3.2 Designer
    44 - B3.3 Commissioning body
    44 - B3.4 Servicing
    45 - B3.5 Commissioning and servicing of electric boilers
    46 - APPENDIX C - TYPE TEST FOR A BOILER SUBJECT TO POWER FAILURE
    46 - C1 GENERAL
    46 - C2 TYPE TEST
    46 - C3 TEST PROCEDURE
    46 - C4 ACCEPTANCE CRITERIA
    47 - APPENDIX D - TYPICAL OIL OR GAS BURNER FIRING SEQUENCE
    48 - APPENDIX E - TYPICAL OIL SUPPLY AND CONTROL SYSTEMS

    Abstract - (Show below) - (Hide below)

    Specifies requirements for boilers which are intended to be operated for periods without human supervision. The changes in this edition include the removal of all references to the regulatory authorities and the introduction of accreditation for boiler attendants, as regulatory authorities will no longer carry out certification of boiler attendants.

    Scope - (Show below) - (Hide below)

    This Standard specifies requirements for unattended and limited attendance boilers which are intended to be operated for periods without human supervision. It includes special features within the control, management and supervision systems, associated valves and fittings, housing and installation, as well as requirements and responsibilities for checking, testing and maintenance of these boilers.The limits on the type, design criteria, and usage of unattended and limited attendance boilers to which this Standard is intended to apply are as follows: (a) Boilers for fixed land installations.(b) Boilers having a design pressure as shown in Table 1.1.(c) Boilers having a power output within the capacity specified in Table 1.1 for the boiler type and category. (See Note 1.) (d) Boilers complying with the supervision and maintenance requirements specified in Table 1.1 for the boiler type and category.(e) Boilers for the generation of steam, or other vapour, for which duty the types of boilers permitted are(i) water-tube type, electric type or small boiler types (see Table 1.1) for unattended operation; and(ii) any type of boiler for limited attendance operation (see Table 1.1).(f) Boilers for the heating of water or other liquids at a pressure above that of the atmosphere and to a temperature not less than the normal atmospheric boiling temperature of the liquid, for which duty any type of boiler complying with AS 1228 is permitted for unattended operation, provided that for other than water-tube and electric type boilers, steam or vapour is not generated in the boiler and the boiler drum or shell is fully flooded.(g) Boilers having any of the following sources of energy input:(i) Gas fuel (mains or other gases).(ii) Oil fuel with a closed flashpoint greater than 23C.(iii) Solid fuels, including solid-fuel-in-suspension.(iv) Waste heat fluids.(v) Electric power.(vi) Solar energy.NOTES:1 This Standard may also be applied to boilers outside the limits specified in Items (a) to (g) in Clause 1.1 where equivalent safety and reliability are ensured.2 Except for definitions in Clause 1.3, other clauses in the Standard refer to steam and water only. The Standard may be applied to other fluids.

    General Product Information - (Show below) - (Hide below)

    Committee ME-001
    Document Type Standard
    Publisher Standards Australia
    Status Superseded
    Superseded By
    Supersedes

    History - (Show below) - (Hide below)

    First published as AS 2593-1983.Second edition 1990.Third edition 1995.Fourth edition 2001. First published as AS 2593-1983. Second edition 1990. Third edition 1995. Fourth edition 2001.

    Standards Referenced By This Book - (Show below) - (Hide below)

    AS 1375-1985 Industrial fuel-fired appliances (known as the SAA Industrial Fuel-fired Appliances Code)
    AS 1228-1997 Pressure equipment - Boilers
    AS/NZS 3788:1996 Pressure equipment - In-service inspection
    AS 3920.1-1993 Assurance of product quality - Pressure equipment manufacture
    AS ISO 1000-1998 The international system of units (SI) and its application
    AS 1768-1991 Lightning protection
    AS 1853-1983 Automatic oil and gas burners - Mechanical draught
    AS 1271-1997 Safety valves, other valves, liquid level gauges, and other fittings for boilers and unfired pressure vessels
    AS 1170.2-1989 Minimum design loads on structures (known as the SAA Loading Code) - Wind loads
    AS/NZS 3000:2000 Electrical installations (known as the Australian/New Zealand Wiring Rules)
    AS 4343-1999 Pressure equipment - Hazard levels
    AS 3873-2001 Pressure equipment - Operation and maintenance
    AS 3892-2001 Pressure equipment - Installation (Reconfirmed 2016)
    AS 3653-1993 Boilers - Safety, management, combustion and other ancillary equipment
    AS 1940-1993 The storage and handling of flammable and combustible liquids

    Standards Referencing This Book - (Show below) - (Hide below)

    AS 3814-2002 (AG 501) Industrial and commercial gas-fired appliances
    AS 1271-2003 Safety valves, other valves, liquid level gauges and other fittings for boilers and unfired pressure vessels
    AS/NZS 3788:2001 Pressure equipment - In-service inspection
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