• AS 2593-1995

    Superseded A superseded Standard is one, which is fully replaced by another Standard, which is a new edition of the same Standard.

    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    Superseded date:  30-06-2017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:  01-01-1995

    Publisher:  Standards Australia

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

    1 - AS 2593-1995 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 Authority having jurisdiction
    8 - 1.3.3 Bed
    8 - 1.3.4 Bed warm-up gas
    8 - 1.3.5 Boilers
    10 - 1.3.6 Boiler management system
    10 - 1.3.7 Accredited boiler attendant
    10 - 1.3.8 Chimney
    10 - 1.3.9 Complete shutdown
    10 - 1.3.10 Double block and vent safety shut-off system
    11 - 1.3.11 Energy input management system
    11 - 1.3.12 Fail-safe
    11 - 1.3.13 Flame detector
    11 - 1.3.14 Flame establishment period
    11 - 1.3.15 Flame failure
    11 - 1.3.16 Flame-proving period
    11 - 1.3.17 Flame simulation
    11 - 1.3.18 Flame supervision system
    11 - 1.3.19 Flue
    11 - 1.3.20 Fuel safety shut-off system
    11 - 1.3.21 Ignition failure
    11 - 1.3.22 Ignition spark period
    11 - 1.3.23 Interlock
    11 - 1.3.24 Interrupted pilot
    11 - 1.3.25 Leakage detection system
    11 - 1.3.26 Lockout
    11 - 1.3.27 Maintenance contract
    12 - 1.3.28 Main fuel
    12 - 1.3.29 Maintenance contractor
    12 - 1.3.30 Manufacturer
    12 - 1.3.31 May
    12 - 1.3.32 Overbed flame
    12 - 1.3.33 Pilot
    12 - 1.3.34 Owner
    12 - 1.3.35 Power output
    12 - 1.3.36 Proved
    12 - 1.3.37 Purging
    12 - 1.3.38 Regulatory Authority
    12 - 1.3.39 Self-checking system
    12 - 1.3.40 Shall
    12 - 1.3.41 Should
    12 - 1.3.42 Start gas flame
    12 - 1.3.43 Supplementary fuel
    12 - 1.3.44 Trained person
    12 - 1.4 NEW DESIGNS, MATERIALS AND CONSTRUCTION METHODS
    13 - SECTION 2 DESIGN AND CONSTRUCTION
    13 - 2.1 GENERAL REQUIREMENTS
    13 - 2.1.1 Basic design
    13 - 2.1.2 Water gauges
    13 - 2.1.3 Tube diameter
    13 - 2.2 STEAM BOILERS (OTHER THAN ELECTRIC BOILERS)
    13 - 2.2.1 General
    13 - 2.2.2 Water-tube steam boilers
    13 - 2.2.3 Steam boilers other than water-tube or electric boilers
    13 - 2.3 HOT WATER BOILERS
    13 - 2.3.1 General
    14 - 2.3.2 Hot water systems
    14 - 2.4 WASTE HEAT BOILERS
    14 - 2.5 ELECTRIC BOILERS
    14 - 2.6 SUPERHEATERS
    15 - SECTION 3 BOILER MANAGEMENT SYSTEM
    15 - 3.1 GENERAL
    15 - 3.2 FAIL-SAFE TECHNIQUES
    15 - 3.3 TEMPERATURE SUITABILITY OF COMPONENTS
    15 - 3.4 COMBUSTION MANAGEMENT
    15 - 3.4.1 General
    15 - 3.4.2 Power-operated valves
    16 - 3.4.3 Flame detectors
    16 - 3.5 WATER MANAGEMENT SYSTEMS
    16 - 3.5.1 For steam boilers other than coil-type forced circulation boilers and electric boilers
    17 - 3.5.2 Water management systems for coil-type forced circulation boilers
    18 - 3.5.3 Water management systems for hot-water boilers
    18 - 3.5.4 Water management systems for waste heat boilers
    18 - 3.5.5 Water management systems for electric boilers
    20 - 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
    21 - 3.9 ALARMS
    21 - 3.10 VISUAL DISPLAY
    21 - 3.10.1 General
    21 - 3.10.2 Fuel-fired boilers
    21 - 3.10.3 Water level security
    22 - 3.11 COMBUSTION EQUIPMENT FOR FUEL-FIRED BOILERS
    22 - 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
    24 - 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
    29 - 4.2.8 Spark ignition period
    29 - 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
    30 - 4.3 SPECIFIC REQUIREMENTS FOR OIL-FIRED BOILERS
    30 - 4.3.1 Oil fuel pretreatment
    30 - 4.3.2 Gas pilot
    30 - 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
    31 - 4.4.1 General
    31 - 4.4.2 Controls and safety devices
    32 - 4.4.3 Valve trains
    32 - 4.4.4 Double block and vent system
    33 - 4.4.5 Premix gas burners
    33 - 4.5 SPECIFIC REQUIREMENTS FOR SOLID-FUEL-IN-SUSPENSION-FIRED BOILERS
    33 - 4.5.1 General
    33 - 4.5.2 Controls and safety devices
    34 - 4.5.3 Valve and piping arrangement
    34 - 4.5.4 Fuel quality
    35 - SECTION 5 ADDITIONAL REQUIREMENTS FOR SOLID-FUEL-FIRED (BED OR GRATE) BOILERS
    35 - 5.1 APPLICATION
    35 - 5.2 OPERATIONAL REQUIREMENTS FOR SOLID FUEL (BED OR GRATE) MANAGEMENT SYSTEMS
    35 - 5.2.1 Pre-start interlocks
    35 - 5.2.2 Start-up
    35 - 5.2.3 Controlled shutdown
    36 - 5.2.4 Fault shutdown
    36 - 5.2.5 Purging
    36 - 5.3 SPECIFIC REQUIREMENTS FOR SOLID-FUEL-FIRED (BED OR GRATE) BOILERS
    36 - 5.3.1 General
    36 - 5.3.2 Fuel quality
    36 - 5.3.3 Combustion equipment
    36 - 5.3.4 Ignition of bed fuel
    36 - 5.3.5 Controls and safety devices
    36 - 5.3.6 Burn-back protection
    37 - 5.3.7 Power failure protection
    37 - 5.3.8 Solid fuel and residue handling plant
    38 - SECTION 6 INSTALLATION
    38 - 6.1 STATUTORY REQUIREMENTS
    38 - 6.1.1 Gas installations
    38 - 6.1.2 Fuel oil installations
    38 - 6.1.3 Solid fuel installations
    38 - 6.1.4 Electrical installations
    38 - 6.2 HOUSING, ACCESS AND SECURITY
    38 - 6.3 FEEDWATER SUPPLY
    38 - 6.4 WATER TREATMENT
    38 - 6.5 BLOWDOWN
    38 - 6.6 FLUES AND CHIMNEYS
    39 - SECTION 7 MARKING AND INSTRUCTIONS
    39 - 7.1 MARKING
    39 - 7.2 ELECTRICAL DATA
    39 - 7.3 INSTRUCTIONS
    39 - 7.4 LANGUAGE AND UNITS
    39 - 7.5 CERTIFICATES
    40 - SECTION 8 CHECKING, TESTING AND MAINTENANCE
    40 - 8.1 GENERAL
    40 - 8.2 ORGANIZATION AND PERSONNEL
    40 - 8.3 RESPONSIBILITIES
    40 - 8.3.1 Program and procedures
    40 - 8.3.2 Daily and weekly checking
    40 - 8.3.3 Periodic and yearly testing and maintenance
    40 - 8.4 CHECKING AND TESTING
    40 - 8.4.1 Limited attendance supervision
    41 - 8.4.2 Daily checking
    41 - 8.4.3 Weekly checking
    41 - 8.4.4 Periodic testing
    42 - 8.4.5 Changes to procedures
    42 - 8.4.6 Recording
    42 - 8.5 MAINTENANCE
    42 - 8.5.1 Periodic maintenance
    42 - 8.5.2 Yearly maintenance
    43 - 8.5.3 Records
    43 - 8.6 RETENTION OF RECORDS
    43 - 8.7 MAINTENANCE CONTRACT
    43 - 8.7.1 General
    43 - 8.7.2 Scope of contract
    43 - 8.7.3 Termination of contract
    44 - APPENDIX A - LIST OF REFERENCED DOCUMENTS
    45 - APPENDIX B - GUIDELINES FOR APPROVAL OF ORGANIZATIONS AND PERSONNEL FOR BOILER CONTROL DESIGN, TESTING AND SERVICING
    45 - B1 GENERAL
    45 - B2 ORGANIZATION, QUALIFICATIONS AND EXPERIENCE
    45 - B3 MINIMUM QUALIFICATIONS FOR PERSONNEL
    45 - B3.1 Design agent
    46 - B3.2 Installation agent
    46 - B3.3 Commissioning agent
    47 - B3.4 Servicing
    48 - APPENDIX C - TYPE TEST FOR A BOILER SUBJECT TO POWER FAILURE
    48 - C1 GENERAL
    48 - C2 TYPE TEST
    48 - C3 TEST PROCEDURE
    48 - C4 ACCEPTANCE CRITERIA
    49 - APPENDIX D - TYPICAL OIL OR GAS BURNER FIRING SEQUENCES
    50 - APPENDIX E - TYPICAL OIL SUPPLY AND CONTROL SYSTEMS
    52 - APPENDIX F - TYPICAL GAS SUPPLY AND CONTROL SYSTEMS

    Abstract - (Show below) - (Hide below)

    Specifies the limits of boiler attendance categories as given in Amendment No.1 to the 1990 edition, together with the extension of the maximum capacity of small low-hazard boilers to 500 kW. It clearly defines the personnel that are involved in the design, installation, commissioning and maintenance of control systems and boilers. Safety is an overriding factor of this Standard and emphasizes the reliable system of control operations.

    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 low hazard type (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 or AS 1797 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.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 and the boiler and its installation are acceptable to the regulatory authority. Current requirements of some regulatory authorities may vary from the criteria given in Table 1.1.2 Except for definitions in Clause 1.3, other clauses in the Standard refer to steam and water only. It is intended that the Standard may be applied to other fluids subject to acceptance by and compliance with any additional safety features required by the regulatory authority.

    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)

    Amendment 1 to AS 2593-1995 see DR 97223. Under Revision see DR 99170 First published as AS 2593-1983.Second edition 1990.Third edition 1995. First published as AS 2593-1983. Second edition 1990. Third edition 1995.

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

    AS 1170.2-1989 Minimum design loads on structures (known as the SAA Loading Code) Wind loads
    AS 1797-1986 Boilers - Fire-tube, shell, and miscellaneous
    AS 1657-1992 Fixed platforms, walkways, stairways and ladders - Design, construction and installation
    AS 3873-1995 Pressure equipment - Operation and maintenance
    AS 1768-1991 Lightning protection
    AS 3000-1986 Electrical installations - Buildings, structures and premises (known as the SAA Wiring Rules)
    AS 1853-1983 Automatic oil and gas burners - Mechanical draught
    AS 2121-1979 The design of earthquake-resistant buildings (known as the SAA Earthquake Code)
    AS 1000-1979 The International System of Units (SI) and its application
    AS 1228-1997 Pressure equipment - Boilers
    AS 1271-1997 Safety valves, other valves, liquid level gauges, and other fittings for boilers and unfired pressure vessels
    AS 3920.1-1993 Assurance of product quality Pressure equipment manufacture
    AS 3788-1990 Boilers and pressure vessels - In-service inspection
    AS 3892-1995 Pressure equipment - Installation
    AS 3653-1993 Boilers - Safety, management, combustion and other ancillary equipment
    AS 1940-1993 The storage and handling of flammable and combustible liquids
    AS 1375-1985 Industrial fuel-fired appliances (known as the SAA Industrial Fuel-fired Appliances Code)
    AS/NZS 1200:1994 Pressure equipment

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

    AS 3873-1995 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/NZS 1200:2000 Pressure equipment
    AS 4037-1992 Boilers and pressure vessels - Examination and testing
    AS 3992-1992 Boilers and pressure vessels - Welding and brazing qualification
    AS/NZS 1200:1994 Pressure equipment
    AS/NZS 3788:1996 Pressure equipment - In-service inspection
    AS 3533.1-1997 Amusement rides and devices - Design and construction
    AS 3533.2-1997 Amusement rides and devices - Operation and maintenance
    AS 3873-2001 Pressure equipment - Operation and maintenance
    AS 3920.1-1993 Assurance of product quality Pressure equipment manufacture
    AS 1271-1997 Safety valves, other valves, liquid level gauges, and other fittings for boilers and unfired pressure vessels
    AS 3814-1998 Code for Industrial and Commercial Gas Fired Appliances
    AS 3892-1995 Pressure equipment - Installation
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