Saturday, 11 October 2025

Code of Ethics BEM / IEM

Understanding the Code of Ethics is crucial because engineering decisions directly affect public safety, environment, and integrity.

Let’s go through this clearly and structured — both for BEM (Board of Engineers Malaysia) and IEM (Institution of Engineers Malaysia), as their codes are closely aligned.


⚖️ 1. PURPOSE OF THE CODE OF ETHICS

The Code of Ethics provides a framework that guides engineers to:

  • Act responsibly in protecting the public interest.
  • Uphold integrity, honesty, and professionalism in all engineering work.
  • Avoid misconduct or conflicts of interest.
  • Promote sustainable and safe engineering practice.

In short:

“Engineers must hold paramount the safety, health, and welfare of the public in the practice of their profession.”


๐Ÿ›️ 2. BEM (Board of Engineers Malaysia) Code of Professional Conduct

The BEM Code is legally binding under Section 15 of the Registration of Engineers Act 1967 (Revised 2015).
Any violation can result in disciplinary action such as suspension, fine, or removal from the register.

Here’s a summary of the 8 main principles:


1️⃣ Responsibility to the Public

  • An engineer must protect public safety, health, and welfare as the highest priority.
  • Avoid designs or works that could cause danger to life or property.
  • If safety is compromised, report the issue to the proper authority.

Example:
If you discover a design flaw that may cause boiler overpressure, you must take steps to stop the operation and report it — even if it delays production.


2️⃣ Competence and Professionalism

  • Only undertake tasks within your competence and experience.
  • Do not misrepresent your qualifications.
  • Keep your knowledge up to date through continuous learning (CPD).

Example:
If you’re a mechanical engineer, don’t sign off on electrical design work unless you’re qualified and competent to do so.


3️⃣ Integrity and Honesty

  • Always act truthfully and transparently.
  • Do not engage in fraud, bribery, or misrepresentation.
  • Do not falsify data, reports, or results.

Example:
Never manipulate test results to meet specifications under client pressure.


4️⃣ Conflict of Interest

  • Avoid situations where personal interest conflicts with professional duty.
  • Disclose potential conflicts to your employer or client.

Example:
If your relative owns a supplier company, you must declare it before recommending them for a project.


5️⃣ Confidentiality

  • Do not disclose confidential information from clients or employers without consent.
  • Protect proprietary or sensitive technical data.

Example:
You cannot share plant performance data of a client with competitors.


6️⃣ Responsibility to Employers and Clients

  • Serve your employer and client faithfully and diligently.
  • But — do not compromise public safety or ethical standards even if instructed.

Example:
If a client asks you to skip a safety test to save cost, you must refuse and explain the professional risk.


7️⃣ Responsibility to Other Engineers

  • Treat fellow engineers with respect and fairness.
  • Do not maliciously criticize or take credit for others’ work.
  • Offer help and mentorship to younger engineers.

Example:
Do not publicly discredit another engineer’s work without valid technical evidence.


8️⃣ Responsibility to the Profession

  • Uphold the dignity and reputation of the engineering profession.
  • Promote awareness of ethical and sustainable practices.
  • Avoid any act that brings disrepute to BEM/IEM.

Example:
Avoid posting unprofessional comments about your company or clients on social media.


๐Ÿงญ 3. IEM (Institution of Engineers Malaysia) Code of Ethics

The IEM Code complements BEM’s legal framework.
It adds emphasis on moral responsibility and professional conduct among members.

It’s grouped into five key obligations:

IEM Code Category Core Meaning
Obligation to Society Prioritize safety, health, and environment above all.
Obligation to Employers/Clients Be honest, loyal, and technically sound.
Obligation to Colleagues Be fair, respectful, and cooperative.
Obligation to the Profession Uphold the honour and advancement of engineering.
Obligation to Self Maintain competence, integrity, and continuous learning.

In essence, BEM = legal enforcement;
IEM = professional moral compass.


๐Ÿง  4. Typical Ethical Questions in IEM Professional Interview

Expect scenarios like these:

  1. Conflict of Interest:

    You are asked to approve a vendor your friend owns. What should you do?
    → Disclose the relationship and let another qualified person make the evaluation.

  2. Safety vs Production Pressure:

    Your manager wants to bypass a safety interlock to maintain production. What will you do?
    → Refuse politely, explain safety and legal risks, and report to a higher authority if needed.

  3. Plagiarism or Misrepresentation:

    A junior submits a report using data from another project. How will you handle it?
    → Investigate, counsel the junior, and correct the record honestly.

  4. Environmental Responsibility:

    A project design may pollute a nearby river. How will you act?
    → Stop the work, evaluate mitigation options, and ensure environmental compliance.


๐Ÿงฉ 5. Key Takeaways for Interview Preparation

✅ Memorize the main principles — safety, honesty, competence, integrity, responsibility.
✅ Practice answering ethical dilemma questions.
✅ Relate ethical values to your real engineering experience — that’s what impresses the interviewers.
✅ Always show you understand that public safety > company profit.

#ProfessionalEngineer #SteamEngineer #msiea #boiler

Code on Painting, Coating, Insulation

Dalam konteks painting, coating dan insulation (salutan, pelapisan dan penebat)


๐ŸŽจ 1. NACE (National Association of Corrosion Engineers)

๐Ÿ”น Pengenalan:

  • NACE International (kini bergabung dengan SSPC menjadi AMPP – Association for Materials Protection and Performance) ialah badan antarabangsa yang menetapkan standard untuk kawalan kakisan, termasuk painting, coating dan lining systems.

  • Standard NACE digunakan secara meluas dalam industri oil & gas, petrokimia, offshore, dan utiliti tenaga.


๐Ÿ”น Tujuan:

Untuk mengawal dan mencegah kakisan melalui pemilihan bahan salutan, persiapan permukaan, dan kaedah aplikasi yang betul.


๐Ÿ”น Standard Utama NACE Berkaitan Painting & Coating:

Kod NACE Tajuk / Skop Kegunaan
NACE SP0169 / ISO 15589 Control of External Corrosion on Underground or Submerged Metallic Piping Systems Pencegahan kakisan pada paip bawah tanah/submerged melalui coating & CP (Cathodic Protection).
NACE SP0178 Design, Fabrication, and Surface Finish Requirements for Metallic Tanks & Vessels Panduan pemilihan dan penyediaan permukaan sebelum coating.
NACE SP0188 Discontinuity (Holiday) Testing of Protective Coatings Kaedah menguji kebocoran pada lapisan coating (holiday test).
NACE SP0198 Coatings & Linings over Concrete Standard untuk aplikasi coating pada permukaan konkrit.
NACE No. 1 / SSPC-SP5 White Metal Blast Cleaning Tahap pembersihan sandblasting tertinggi sebelum coating.
NACE No. 2 / SSPC-SP10 Near-White Blast Cleaning Tahap pembersihan hampir sempurna untuk persediaan sebelum epoxy coating.
NACE No. 3 / SSPC-SP6 Commercial Blast Cleaning Tahap pembersihan sederhana.
NACE No. 4 / SSPC-SP7 Brush-Off Blast Cleaning Tahap pembersihan ringan untuk kerja penyelenggaraan.

๐Ÿ”น Kaitan Dengan Industri:

  • Semasa fabricasi atau maintenance boiler, vessel, atau pipeline, standard NACE digunakan untuk memastikan coating dapat bertahan terhadap:

    • Suhu tinggi,

    • Kimia agresif,

    • Kondisi lembap atau air masin,

    • Persekitaran korosif (CO₂, H₂S, chlorides).


๐Ÿ”น Contoh Penggunaan:

  • Internal lining tangki storage crude oil: Guna NACE SP0198 untuk memastikan lapisan epoxy sesuai dan tahan lama.

  • External pipeline: Guna NACE SP0169 untuk kombinasi coating + cathodic protection.


๐Ÿงฑ 2. CINI (Comitรฉ International du Nรฉgoce et de l'Industrie)

๐Ÿ”น Pengenalan:

  • CINI bermaksud “Commission Insulation Industry Netherlands”, iaitu standard antarabangsa (Eropah) yang memberi garis panduan kejuruteraan dan pemasangan sistem penebat (insulation systems).

  • Rujukan utama: CINI Manual, diterbitkan oleh Stichting CINI (Netherlands Foundation for Insulation Standards).


๐Ÿ”น Tujuan:

Untuk memastikan kualiti, keselamatan, dan kecekapan tenaga dalam kerja thermal insulation bagi:

  • Loji penapisan minyak,

  • Loji kimia dan petrokimia,

  • Stesen janakuasa,

  • Sistem HVAC industri.


๐Ÿ”น Kandungan Utama CINI Manual:

Bahagian (Section) Fokus / Kandungan
CINI 1.1 – 1.3 Prinsip umum insulation, definisi, klasifikasi bahan.
CINI 2.1 – 2.3 Keperluan bahan penebat untuk suhu rendah, sederhana, tinggi.
CINI 3.1 – 3.3 Kaedah pemasangan paip, vessel, tangki dan peralatan.
CINI 4.x Perlindungan mekanikal luar (cladding, jacketing, finishing).
CINI 5.x Pencegahan kakisan bawah penebat (CUI – Corrosion Under Insulation).
CINI 6.x Penebat sejuk (cryogenic insulation).
CINI 7.x Penebat akustik dan kebakaran.
CINI 8.x Ujian kualiti dan dokumentasi pemasangan.

๐Ÿ”น Kaitan Dengan Industri:

  • Insulation pada paip wap, tangki, dan boiler mesti ikut CINI Manual bagi memastikan:

    • Penebat tahan suhu & kimia,

    • Elak CUI (corrosion under insulation),

    • Penjimatan tenaga (minimize heat loss),

    • Pemasangan selamat dan kemas.


๐Ÿ”น Contoh:

  • CINI 2.1.01 – pemilihan bahan insulation suhu tinggi (misalnya mineral wool, calcium silicate).

  • CINI 5.2.01 – perlindungan anti-kakisan sebelum pasang insulation pada paip.

  • CINI 4.1.02 – jenis cladding (aluminium, stainless steel, PVC) dan ketebalan.


⚙️ Kesimpulan Perbandingan

Aspek NACE CINI
Asal / Organisasi USA (AMPP – NACE International) Belanda (Stichting CINI)
Fokus Utama Coating, Painting, Corrosion Control Insulation Systems (Thermal, Acoustic, Cryogenic)
Digunakan Dalam Oil & Gas, Offshore, Petrochemical Refinery, Power Plant, Petrochemical
Skop Surface prep, coating, inspection Material selection, installation, anti-CUI
Jenis Dokumen Standards (SP, TM, No.) CINI Manual (Sections 1–8)

#code #asme

Boiler material and Code

Mari kita jelaskan satu per satu tentang ASME Section II dan API 571, sebab kedua-duanya sangat penting dalam bidang bahan (materials) dan penilaian kerosakan (damage assessment) dalam industri seperti loji kuasa dan kilang sawit.


๐Ÿ”ง 1. ASME Section II – Materials

Tujuan utama:
Memberi standard bahan (materials standards) untuk fabrikasi dan reka bentuk peralatan tekanan (pressure equipment) seperti boiler, pressure vessel, piping system, dan heat exchanger.

ASME Section II dibahagikan kepada empat bahagian utama:

Bahagian Kandungan Penjelasan
Part A Ferrous Materials Mengandungi senarai spesifikasi bahan besi seperti carbon steel, low alloy steel, dan stainless steel. Contoh: SA-516 Gr.70, SA-240 Type 304.
Part B Non-Ferrous Materials Untuk bahan bukan ferrous seperti tembaga, nikel, aluminium, titanium, dan aloi lain.
Part C Welding Rods, Electrodes, and Filler Metals Spesifikasi untuk bahan pengelasan seperti elektrod, filler rod, dan wire (contohnya: SFA-5.1 untuk SMAW electrode).
Part D Properties (Allowable Stresses) Jadual nilai kekuatan tegangan, tegasan benarkan, modulus keanjalan, dan sifat fizikal bahan pada pelbagai suhu. Digunakan oleh designer untuk pengiraan reka bentuk.

๐Ÿ“˜ Kegunaan di loji atau reka bentuk boiler:

  • Menentukan grade bahan yang digunakan untuk drum, tube, header, piping.

  • Menentukan tekanan maksimum dibenarkan (allowable stress) berdasarkan suhu operasi.

  • Menentukan bahan filler welding yang sesuai dengan base material.


⚙️ 2. API 571 – Damage Mechanisms Affecting Fixed Equipment in the Refining Industry

Tujuan utama:
Memberi panduan mengenal pasti, memahami, dan menilai pelbagai mekanisme kerosakan (damage mechanisms) yang boleh berlaku pada peralatan tetap (fixed equipment) seperti vessel, boiler, dan heat exchanger.

Kandungan utama API 571:

  1. Pengenalan kepada Damage Mechanism

    • Membezakan antara degradation, corrosion, cracking, dan mechanical damage.

    • Setiap mekanisme diterangkan dari segi penyebab, bahan terlibat, kondisi operasi, simptom, dan langkah mitigasi.

  2. Kategori Damage Mechanisms
    Terdapat lebih daripada 60 jenis kerosakan yang dihuraikan, dibahagi kepada beberapa kumpulan utama:

    Kategori Contoh Damage Mechanism Penjelasan Ringkas
    Mechanical / Metallurgical Failure Fatigue, Creep, Brittle Fracture Kegagalan akibat tegasan mekanikal dan suhu tinggi.
    High Temperature Corrosion Sulfidation, Oxidation, Carburization Berlaku pada suhu tinggi (>400°C). Contohnya pada superheater boiler.
    Low Temperature Corrosion Hydrogen Embrittlement, Wet H₂S Berlaku pada suhu rendah dengan kehadiran air atau gas reaktif.
    Aqueous Corrosion Uniform corrosion, Pitting, Crevice Disebabkan air, asid, atau kelembapan.
    Microbiologically Influenced Corrosion (MIC) Bakteria sulfur, iron bacteria Disebabkan aktiviti mikroorganisma.
    Environmental Cracking SCC (Stress Corrosion Cracking), HIC Berlaku akibat kombinasi tegasan dan persekitaran kimia.
  3. Tujuan dalam industri:

    • Digunakan dalam Risk Based Inspection (RBI) dan Fitness for Service (FFS).

    • Membantu menentukan jenis pemeriksaan NDT yang sesuai (contohnya, UT untuk creep, PT untuk SCC).

    • Panduan untuk root cause failure analysis (RCFA).


๐Ÿ” Hubungan antara ASME Sec II & API 571

Aspek ASME Sec II API 571
Fokus Spesifikasi dan sifat bahan Mekanisme kerosakan bahan
Gunaan Semasa reka bentuk dan fabrikasi Semasa operasi, pemeriksaan, dan penyelenggaraan
Tujuan Pastikan bahan sesuai dan selamat untuk tekanan/suhu tertentu Kenal pasti dan kawal kerosakan sepanjang hayat peralatan

๐Ÿงฉ Contoh dalam konteks loji sawit atau boiler:

  • ASME Sec II digunakan semasa memilih bahan SA-210 Gr A1 untuk superheater tube.

  • Selepas beberapa tahun operasi, jika tube retak, jurutera akan rujuk API 571 untuk menentukan sama ada puncanya ialah creep, oxidation, atau sulfidation corrosion.

#sabah #boiler #SteamEngineer #asme #code 

Boiler Refractory and Code

๐Ÿ”ฅ 1. API 936 – Refractory Installation Quality Control – Inspection and Testing Monolithic Refractory Linings and Materials

Purpose:

API Standard 936 provides the minimum requirements for quality assurance and control of monolithic refractory installations — from material selection, mixing, installation, curing, to drying.

This standard ensures that refractory linings (castables, plastics, gunnite, etc.) are installed safely, consistently, and perform reliably in high-temperature services (like furnaces, reformers, or boilers).


Scope & Coverage:

  • Applies to monolithic refractories, not brick linings.

  • Covers specification, testing, installation, curing, and drying procedures.

  • Emphasizes quality control and inspection requirements.


Key Areas in API 936:

Section Description
Material Qualification Defines requirements for raw materials (castables, binders, aggregates) to ensure they meet chemical & physical specs.
Pre-Installation Checks Inspection of forms, anchors, mixing water, environment, and equipment before lining.
Mixing & Placing Specifies methods for mixing castable materials, gunning, ramming, or shotcreting.
Curing Defines required curing time, humidity, and temperature before drying.
Dry-Out Procedures Controls heating-up schedule to remove moisture safely and avoid spalling or cracking.
Testing & Acceptance Requires compressive strength tests, density, permeability, and visual inspection.
Inspector Qualification API 936 also defines qualification for refractory inspectors (API 936 certification).

Typical Application Areas:

  • Fired heaters

  • Reformers and furnaces

  • Fluid catalytic cracking units (FCCU)

  • Boiler combustion chambers

  • Incinerators


Why It Matters:

Poor refractory installation is a major cause of premature failure in fired equipment. API 936 ensures:

  • Consistency in material quality

  • Correct installation technique

  • Controlled curing and dry-out

  • Documentation for traceability


๐Ÿ”ง 2. API 982 – Refractory Linings in Fired Process Equipment in General Refinery and Petrochemical Service

Purpose:

API 982 gives engineering and design guidance for refractory linings in fired process equipment, focusing on material selection, design, and application to achieve long-term performance and reliability.

While API 936 focuses on installation quality, API 982 focuses on design and material engineering.


Scope & Coverage:

  • Provides best practices for selection, design, and maintenance of refractory systems.

  • Applicable to fired heaters, reformers, incinerators, sulfur recovery units (SRU), and similar high-temperature equipment.


Key Topics in API 982:

Section Description
Refractory Material Selection Guidance on selecting correct type (dense, insulating, low-cement, etc.) based on service condition.
Lining Design Includes thickness, anchoring system, expansion joints, and thermal stress considerations.
Thermal Performance Thermal conductivity, heat loss calculations, and temperature profiles.
Mechanical Design Addresses stresses due to thermal expansion, vibration, or structural loads.
Anchor Design Selection of anchor materials, shapes, spacing, and welding practices.
Installation Practices (reference to API 936) Advises following API 936 for QA/QC and inspection.
Maintenance and Repair Inspection intervals, damage mechanisms (spalling, chemical attack, erosion), and repair recommendations.

Differences Between API 936 & API 982

Aspect API 936 API 982
Focus Installation quality, inspection, testing Design, engineering, material selection
Users Refractory inspectors, contractors Engineers, designers, plant reliability teams
Covers Procedures for mixing, curing, testing Thermal, mechanical, chemical design aspects
Stage Construction / QA phase Design / Engineering phase
Certification API 936 Inspector certification available No certification program

Summary Analogy:

  • API 982“Design the refractory system correctly.”

  • API 936“Install and test the refractory system correctly.”

#steamengineer #boiler #code #api #asme

Combustion and related Code

๐Ÿ”ฅ Combustion & BMS (Burner Management System) Related Codes and Standards

1. IEC 61511 – Functional Safety for Process Industry

  • Tajuk penuh: Functional safety – Safety instrumented systems for the process industry sector

  • Fokus utama:

    • Standard ini merujuk kepada reka bentuk, pemasangan, operasi dan penyelenggaraan sistem keselamatan berinstrumentasi (SIS) seperti Burner Management System (BMS).

    • Menekankan Safety Integrity Level (SIL) untuk setiap fungsi keselamatan.

  • Kegunaan dalam BMS:

    • Menentukan tahap keselamatan automasi (contohnya SIL 2 untuk shutdown burner).

    • Memastikan sistem seperti flame detector, fuel shutoff valve dan PLC BMS memenuhi tahap SIL tertentu.


2. IEC 60730-2-5 – Automatic Electrical Controls for Household and Similar Use

  • Tajuk penuh: Part 2-5: Particular requirements for automatic electrical burner control systems

  • Fokus utama:

    • Menentukan keperluan keselamatan dan prestasi untuk sistem kawalan automatik pembakar (burner control unit).

    • Diterapkan terutamanya untuk domestic dan light commercial burner.

  • Kegunaan dalam BMS:

    • Mengawal fungsi seperti ignition, flame supervision, dan fail-safe dalam burner kecil.


3. EN 230 – Automatic Burner Control Systems for Oil Burners

  • Fokus utama:

    • Standard Eropah untuk burner bahan api cecair (oil-fired).

    • Menetapkan syarat untuk kawalan automatik termasuk:

      • Urutan penyalaan (start-up sequence)

      • Pengawasan nyalaan (flame monitoring)

      • Shutdown automatik apabila berlaku kegagalan

  • Kegunaan dalam BMS:

    • Untuk sistem minyak sawit atau minyak diesel bagi auxiliary burner.


4. EN 298 – Automatic Burner Control Systems for Gas Burners

  • Fokus utama:

    • Sama seperti EN 230 tetapi untuk gas-fired burners.

    • Termasuk syarat untuk kawalan penyalaan, pemantauan api, keselamatan shutdown, dan restart.

  • Kegunaan dalam BMS:

    • Digunakan pada sistem burner gas di boiler atau process heater.


5. EN 746 – Industrial Thermoprocessing Equipment

  • Fokus utama:

    • Standard ini merangkumi keseluruhan peralatan pemprosesan haba industri, termasuk:

      • Relau (furnace)

      • Incinerator

      • Thermal oxidizer

    • Bahagian EN 746-2 sangat relevan untuk combustion and fuel handling systems.

  • Kegunaan dalam BMS:

    • Menentukan keperluan keselamatan sistem bahan api (fuel train), kawalan pembakar, dan langkah pencegahan letupan.


6. EN 50156 – Electrical Equipment for Furnaces and Associated Heating Processes

  • Fokus utama:

    • Standard untuk keselamatan sistem elektrik dan kawalan pada peralatan pembakaran industri.

    • Menyentuh tentang design, installation, operation & maintenance.

  • Kegunaan dalam BMS:

    • Menetapkan keperluan bagi wiring, sensor, dan control system agar selamat digunakan dalam persekitaran panas dan berisiko letupan.


7. EN 12952-8 – Water-Tube Boilers: Requirements for Firing Systems

  • Fokus utama:

    • Bahagian ke-8 dalam siri EN 12952 untuk boiler air-tube.

    • Menyediakan keperluan reka bentuk dan keselamatan untuk firing system dan control system.

    • Termasuk:

      • Ignition sequence

      • Flame detection

      • Fuel shut-off

      • Purging sequence

  • Kegunaan dalam BMS:

    • Rujukan utama bagi sistem kawalan pembakaran di boiler industri.


8. ISO 13577-2 – Industrial Furnaces and Associated Processing Equipment

  • Tajuk penuh: Part 2: Safety requirements for combustion and fuel handling systems

  • Fokus utama:

    • Menyediakan panduan keselamatan global untuk combustion system design, termasuk fuel train, air supply, dan safety interlocks.

    • Harmonized dengan EN 746-2.

  • Kegunaan dalam BMS:

    • Untuk memastikan sistem pembakaran direka mengikut standard antarabangsa yang diiktiraf (bukan hanya Eropah).


9. NFPA 85 – Boiler and Combustion Systems Hazards Code

  • Fokus utama:

    • Diterbitkan oleh National Fire Protection Association (USA).

    • Standard paling penting di Amerika untuk keselamatan boiler, burner, dan pressure system.

    • Menyentuh:

      • Start-up/shutdown sequence

      • Flame safeguard

      • Fuel trip logic

      • Purging requirements

  • Kegunaan dalam BMS:

    • Digunakan secara meluas di loji tenaga, refinery, dan kilang proses di seluruh dunia.


10. API 556 – Instrumentation and Control Systems for Fired Heaters and Boilers

  • Fokus utama:

    • Standard API untuk instrumentasi dan kawalan sistem pemanas (fired heater, boiler).

    • Merangkumi:

      • Combustion control

      • Burner management

      • Safety shutdown system

    • Diselaraskan dengan IEC 61511 (SIS) dan NFPA 85.

  • Kegunaan dalam BMS:

    • Rujukan industri minyak & gas bagi sistem kawalan pembakaran dan keselamatan integrasi.


๐Ÿ“˜ Kesimpulan Ringkas:

Standard / Code Kawasan Fokus Digunakan Untuk
IEC 61511 Functional safety (SIL) SIS & BMS di industri proses
IEC 60730-2-5 Electrical control safety Burner kecil (domestic/komersial ringan)
EN 230 Oil burner controls Pembakar minyak
EN 298 Gas burner controls Pembakar gas
EN 746 Industrial furnace safety Sistem pembakaran industri
EN 50156 Electrical safety Peralatan pemanas industri
EN 12952-8 Boiler firing system Boiler air-tube
ISO 13577-2 Combustion & fuel safety Relau & sistem bahan api industri
NFPA 85 Combustion hazard control Boiler besar & loji tenaga
API 556 Instrumentation & control Fired heater / refinery boiler

#boiler #en #code #iso #nfpa 

Pressure Valve and Code

๐Ÿงฉ 1. API 520 – Sizing, Selection, and Installation of Pressure-Relieving Devices

Full title: API Standard 520, Parts I & II

๐Ÿ”น Part I – Sizing and Selection

  • Focuses on how to correctly size and select a PSV or PRV (Pressure Relief Valve).

  • Ensures the valve can release sufficient flow to prevent system overpressure.

  • Covers:

    • Sizing formulas for gas, vapor, steam, and liquid service

    • Determination of set pressure and overpressure

    • Backpressure effects and correction factors

    • Capacity correction for different fluids and conditions

    • Selection of valve type (spring-loaded, pilot-operated, etc.)

Application: Used during design stage of boilers, pressure vessels, and process lines to calculate the right PSV or rupture disc capacity.


๐Ÿ”น Part II – Installation

  • Provides guidance on how to install the PSV safely and effectively.

  • Covers:

    • Piping configuration for inlet and outlet

    • Reaction forces and supports for discharge lines

    • Minimizing pressure drop in inlet lines (≤ 3% of set pressure)

    • Ensuring drainage, venting, and safe discharge locations

Application: Used during construction and commissioning — ensures installation follows best practices to maintain reliability and accuracy of PSV performance.


๐Ÿงฉ 2. API 521 – Pressure-Relieving and Depressuring Systems

Full title: API Standard 521, Pressure-Relieving and Depressuring Systems

๐Ÿ”น Purpose:

  • Focuses on system-level design of relief and flare systems — not the valve itself.

  • Ensures the entire relief system (valves, headers, flare stacks) can handle the worst-case scenario.

๐Ÿ”น Key Topics:

  • Identification of overpressure scenarios, e.g.:

    • Fire exposure

    • Blocked outlet

    • Thermal expansion

    • Control valve failure

  • Relief load calculation methods

  • Depressuring systems design (for emergency shutdown)

  • Flare and vent system design, including:

    • Flare tip sizing

    • Knockout drum sizing

    • Noise, radiation, and dispersion control

Application: Used during HAZOP, relief load study, or flare network design — ensures the plant can safely relieve excess pressure to atmosphere or flare.


๐Ÿงฉ 3. API 576 – Inspection of Pressure-Relieving Devices

Full title: API Recommended Practice 576, Inspection of Pressure-Relieving Devices

๐Ÿ”น Purpose:

  • Provides inspection, testing, and maintenance procedures for PSVs and rupture discs.

  • Ensures the device remains functional and reliable throughout its service life.

๐Ÿ”น Key Sections:

  • Inspection intervals (based on service conditions and history)

  • Testing methods: bench testing, pop testing, seat leakage testing

  • Common failure modes: corrosion, seat leakage, spring fatigue, blockage

  • Documentation & tagging requirements for traceability

Application: Used during plant maintenance or turnaround (TA) — guides inspection intervals, testing frequency, and certification process of PSV.


⚙️ Summary Table

API Code Focus Area Stage of Use Key Application
API 520 Sizing, selection, and installation Design & commissioning To select the right PSV and install properly
API 521 System design & relief scenarios Design & HAZOP To size flare systems and determine relief loads
API 576 Inspection, testing, and maintenance Operation & maintenance To ensure reliability and compliance of PSV

#API #steamengineer #boiler #code

Boiler Commissioning and Code

Let’s go through VGB 513, which is an important European standard guideline for boiler commissioning and operation—particularly for steam and hot-water generation systems.


๐Ÿ”ง VGB-S-513 – Commissioning of Steam Boiler Plants

๐Ÿข Publisher / Organization

Issued by VGB PowerTech e.V., Germany — a recognized technical association for power and industrial plant operations.
It’s widely used across Europe, the Middle East, and industrial boiler sectors where EN and DIN codes apply.


๐Ÿ“˜ Full Title

VGB-S-513: Commissioning of Steam Boiler Plants (Inbetriebsetzung von Dampferzeugungsanlagen)

(Previously known as VGB-R 513 until it was converted to the new “VGB-S” format.)


๐ŸŽฏ Purpose of the Code

VGB 513 provides systematic guidance for safe, efficient, and reliable commissioning of steam or hot water boilers—from the completion of fabrication until normal operation begins.

The goal is to ensure:

  • Correct assembly and function of all systems,

  • Proper cleaning and flushing,

  • Safe startup and control testing,

  • Compliance with operational safety and efficiency requirements.


⚙️ Main Sections / Contents Overview

1️⃣ Pre-Commissioning Preparation

  • Inspection of fabrication, welding, hydrostatic tests.

  • Verification of instrumentation, valves, safety devices.

  • Documentation checks (drawings, certificates, test reports).

  • Boiler internals cleaning: chemical cleaning, pickling, or steam blowing.

2️⃣ Water-Side Preparation

  • Boiler feedwater treatment and quality verification (in line with VGB-S-010-T-00 “Feedwater, Boiler Water and Steam Quality”).

  • First filling and deaeration procedures.

3️⃣ Steam-Side Cleaning

  • Steam blowing procedures:

    • Establishes cleanliness of superheaters, steam lines, and turbines.

    • Describes target pressure ratios, cleaning indicators, and acceptance criteria.

4️⃣ Functional Tests

  • Testing of:

    • Safety valves, interlocks, limit switches, and burner management systems.

    • Control loops (pressure, temperature, water level).

    • Alarm and shutdown systems.

5️⃣ Initial Firing and Heat-Up

  • Controlled heating rate to avoid thermal stresses.

  • Recording of expansion, vibration, and drum differential temperatures.

  • Monitoring of emissions, draft, and combustion efficiency.

6️⃣ Performance & Efficiency Tests

  • Boiler output verification (steaming rate).

  • Flue gas analysis for combustion efficiency.

  • Heat balance calculation.

7️⃣ Documentation & Handover

  • Recording all test results, commissioning data, and parameter settings.

  • Preparing commissioning report and operational manual for the plant owner.


๐Ÿง  Why VGB 513 Is Important

  • Provides uniform European standard for all boiler commissioning activities.

  • Reduces risk of accidents and premature tube failures during startup.

  • Ensures coordination between mechanical, electrical, and control engineers.

  • Often used together with:

    • EN 12952 / EN 12953 (boiler design & construction)

    • DIN EN 764 (pressure equipment)

    • VGB-S-010-T-00 (water and steam quality)

    • ASME Section I (when plant is mixed-code system)


๐Ÿงฉ In Summary

Section Focus Purpose
Pre-commissioning Inspection, documentation Ensure readiness
Cleaning Steam & water side Remove contamination
Functional testing Controls & safety Verify operation
Firing & heat-up Controlled startup Avoid stress & damage
Performance test Efficiency & output Validate design values
Handover Reports & data Transfer to operation

#asme #code #boiler

Boiler Fabrication & Code

๐Ÿ”ง 1. ASME Section IX – Welding and Brazing Qualifications

Tujuan:
Menetapkan keperluan kelayakan untuk kimpalan dan kimpalan pateri (brazing).

Fokus utama:

  • WPS (Welding Procedure Specification): Prosedur yang perlu diuji & diluluskan sebelum digunakan.

  • PQR (Procedure Qualification Record): Bukti keputusan ujian WPS.

  • Welder Performance Qualification (WPQ): Menilai kemahiran tukang kimpal individu.

Kaitan dengan boiler fabrication:
Setiap sambungan dikimpal pada dandang mesti ikut WPS & PQR yang sah menurut ASME Sec IX untuk menjamin kekuatan dan keselamatan tekanan operasi.


๐Ÿงฐ 2. ASME PCC-1 – Guidelines for Pressure Boundary Bolted Flange Joint Assembly

Tujuan:
Memberi panduan untuk pemasangan flange dan bolt bagi memastikan sambungan tekanan tinggi tidak bocor.

Fokus utama:

  • Kaedah torque bolt.

  • Penggunaan gasket & pelincir bolt.

  • Pengurusan kelonggaran bolt (bolt relaxation).

  • Prosedur pemasangan flange selamat.

Kaitan dengan boiler fabrication:
Digunakan semasa penyambungan manhole, header, valve, steam drum dan piping flange pada boiler system.


⚙️ 3. ASME PCC-2 – Repair of Pressure Equipment and Piping

Tujuan:
Memberi panduan cara membaiki peralatan tekanan & paip tanpa mengubah reka bentuk asal.

Fokus utama:

  • Weld repair, mechanical clamp, composite wrap.

  • Pressure testing selepas pembaikan.

  • Penilaian integrity selepas repair.

Kaitan:
Digunakan apabila terdapat retakan, korosi, atau kebocoran pada shell atau header boiler yang masih boleh dibaiki.


๐Ÿ”ฅ 4. API 577 – Welding Inspection and Metallurgy

Tujuan:
Panduan daripada American Petroleum Institute (API) untuk pemeriksaan kimpalan dalam peralatan tekanan.

Fokus utama:

  • Asas metallurgy semasa welding.

  • Defect recognition oleh welding inspector.

  • Peranan Welding Inspector & Welding Engineer.

Kaitan:
Memberi panduan tambahan kepada ASME Sec IX terutama dalam industri minyak & gas, digunakan oleh welding inspector ketika pembuatan atau pemeriksaan boiler.


๐Ÿงช 5. ASME Section V – Nondestructive Examination (NDE)

Tujuan:
Menetapkan keperluan ujian tanpa musnah (NDT) untuk menilai kualiti sambungan dikimpal.

Kaedah termasuk:

  • Radiographic Test (RT)

  • Ultrasonic Test (UT)

  • Magnetic Particle Test (MT)

  • Liquid Penetrant Test (PT)

Kaitan:
Semua sambungan kritikal (seperti drum, header, nozzle) mesti diuji NDE sebelum diterima dalam boiler fabrication.


๐Ÿ” 6. ISO 9712 – Qualification and Certification of NDT Personnel

Tujuan:
Menetapkan standard antarabangsa untuk kelayakan juruteknik NDT.

Fokus utama:

  • Level 1, 2, dan 3 certification untuk NDT (RT, UT, MT, PT, VT).

  • Penilaian kemahiran & pengetahuan operator NDT.

Kaitan:
Operator yang melakukan NDE pada komponen boiler mesti mempunyai sijil ISO 9712 yang sah.


๐Ÿ’ง 7. ISO 3452-1 – Penetrant Testing

Tujuan:
Standard antarabangsa untuk ujian cecair penembus (PT) bagi mengesan retakan halus di permukaan logam.

Fokus utama:

  • Jenis penetrant (fluorescent / visible dye).

  • Prosedur pembersihan & penilaian.

  • Keperluan sensitiviti & kebersihan permukaan.

Kaitan:
Digunakan untuk memeriksa permukaan weld pada drum, header, atau nozzle untuk kesan retakan mikro selepas kimpalan.


๐Ÿงฏ 8. ASME B31.1 – Power Piping

Tujuan:
Menetapkan reka bentuk, pembuatan & pemasangan piping sistem kuasa (power piping), termasuk yang menyambung ke boiler.

Fokus utama:

  • Stress analysis pada piping.

  • Support & expansion loop design.

  • Pressure testing requirement.

Kaitan:
Digunakan untuk steam line, feedwater line, blowdown line, condensate line dalam sistem boiler.


9. ASME B16.5 – Pipe Flanges and Flanged Fittings

Tujuan:
Menentukan dimensi, rating tekanan, bahan, dan toleransi flange & fitting.

Fokus utama:

  • Flange class rating (150, 300, 600, dll).

  • Dimension bolt holes, gasket seating, face type (RF, RTJ).

  • Bahan (A105, F316, dsb).

Kaitan:
Flange yang digunakan dalam sistem boiler dan piping mesti ikut B16.5 supaya padan dengan tekanan dan suhu operasi.


๐Ÿ—️ Kesimpulan Ringkas

Kod / Standard Fokus Utama Aplikasi Dalam Boiler
ASME Sec IX Welding qualification Pembuatan sambungan kimpalan
PCC-1 Bolted flange assembly Sambungan flange tekanan tinggi
PCC-2 Repair & alteration Pembaikan boiler & piping
API 577 Welding inspection Pemeriksaan & kawalan kimpalan
ASME Sec V NDE methods Pemeriksaan mutu sambungan
ISO 9712 Certify NDT personnel Kelayakan operator NDT
ISO 3452-1 Penetrant testing Ujian retak permukaan weld
ASME B31.1 Power piping design Steam & feedwater piping
ASME B16.5 Flange dimensions Flange & fitting connection

#asme #code #steamengineer 

Boiler and Design Code

๐Ÿ”น 1. ASME Section I – Power Boilers

๐Ÿ“˜ American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, Section I
Digunakan untuk boiler stim tekanan tinggi (power boiler) — contohnya dandang di kilang sawit, loji janakuasa, atau refinery.

➤ Skop:

  • Reka bentuk, fabrikasi, pemeriksaan & pengujian boiler yang menghasilkan stim >15 psi (100 kPa).

  • Meliputi komponen: drum, header, superheater, economizer, reheater.

➤ Ciri utama:

  • Perlu ASME “S” Stamp untuk pengesahan reka bentuk & pembinaan.

  • Mengawal:

    • Material (SA-516, SA-210, dll)

    • Pengiraan tekanan reka bentuk

    • Prosedur kimpalan & ujian nondestructive (RT, UT)

    • Ujian hidrostatik & safety valve settings

๐Ÿ‘‰ Kesimpulan: Kod utama untuk reka bentuk & pembinaan boiler stim industri.


๐Ÿ”น 2. EN / BS Code (European / British Standard)

Digunakan di Eropah atau peralatan import ke Malaysia yang mematuhi European Pressure Equipment Directive (PED).

➤ Contoh Kod:

  • BS 2790: Shell-type steam boilers.

  • EN 12952: Water-tube boilers.

  • EN 12953: Shell boilers.

➤ Ciri utama:

  • Memastikan reka bentuk memenuhi “Essential Safety Requirements (ESR)” di bawah PED.

  • Kod ini digunakan jika boiler dikeluarkan dari Eropah (dengan CE marking).

๐Ÿ‘‰ Kesimpulan: Kod setara kepada ASME, tapi digunakan untuk pasaran Eropah & UK.


๐Ÿ”น 3. ASME Section VII – Recommended Guidelines for the Care of Power Boilers

๐Ÿ“— Ini BUKAN kod reka bentuk, tetapi panduan pengoperasian & penyelenggaraan boiler stim selepas dibina.

➤ Kandungan:

  • Tatacara startup & shutdown boiler dengan selamat.

  • Langkah emergency handling & troubleshooting.

  • Pemeriksaan berkala, logbook operation, dan latihan operator.

๐Ÿ‘‰ Kesimpulan: Fokus kepada keselamatan operasi & penjagaan selepas reka bentuk.


๐Ÿ”น 4. ASME Section VIII – Pressure Vessels

Kod ini untuk vessel bertekanan, bukan boiler secara langsung.
Namun ia sangat penting sebab komponen sokongan boiler seperti deaerator, air receiver, oil tank, dan heat exchanger dibina di bawah kod ini.

➤ Dibahagi kepada:

  • Division 1: Reka bentuk konvensional (design by rule).

  • Division 2: Reka bentuk berasaskan analisis (design by analysis).

  • Division 3: Vessel tekanan tinggi (>10,000 psi).

๐Ÿ‘‰ Kesimpulan: Digunakan untuk pressure part selain boiler utama, tetapi tetap dalam sistem boiler plant.


๐Ÿ”น 5. EN 12952 – Water Tube Boilers

๐Ÿ“™ Kod Eropah khusus untuk boiler jenis water-tube (air dalam tiub, gas panas di luar).

➤ Skop:

  • Reka bentuk mekanikal & kekuatan struktur (drum, header, tubes).

  • Pemeriksaan, ujian tekanan, dan safety devices.

  • Sambungan ke sistem bantu (auxiliary systems) seperti feedwater & blowdown.

➤ Bahagian Utama:

  • EN 12952-1: General

  • EN 12952-3: Design & calculation

  • EN 12952-6: Inspection, testing & documentation

๐Ÿ‘‰ Kesimpulan: Kod utama untuk reka bentuk water-tube boiler mengikut piawaian Eropah.


๐Ÿ”น 6. DIN 2391 – Seamless Precision Steel Tubes

๐Ÿ“˜ Kod Jerman (Deutsches Institut fรผr Normung) untuk paip keluli tanpa jahitan (seamless tubes).

➤ Skop:

  • Menetapkan komposisi kimia, toleransi, kekuatan tegangan, dan permukaan untuk paip tekanan tinggi.

  • Digunakan pada bahagian:

    • Superheater tubes

    • Economizer tubes

    • Boiler feed lines

➤ Jenis bahan biasa:

  • DIN 2391 St 35, St 45, St 52 – sesuai untuk suhu tinggi & tekanan tinggi.

๐Ÿ‘‰ Kesimpulan: Standard bahan mentah (material specification), bukan kod reka bentuk keseluruhan.


⚙️ Ringkasan Keseluruhan Kod Boiler

Kod / Standard Jenis Kod Fokus / Skop Aplikasi
ASME Sec I Design & Fabrication Power Boiler (high pressure steam) Dandang industri
ASME Sec VII Operation Guideline Penyelenggaraan & operasi selamat Semua boiler
ASME Sec VIII Design & Fabrication Pressure Vessel (non-boiler) Air receiver, deaerator
EN / BS Code European Design CE marking, safety compliance Boiler import dari Eropah
EN 12952 Design Water-tube boiler Loji tenaga / kilang besar
DIN 2391 Material Standard Seamless steel tube Tiub superheater, economizer

#asme #code #boiler #en #din #bs

Dukun Boiler — Api Semangat yang Tak Pernah Padam


Aku masih ingat, sekitar tahun 2007 kalau tak silap.
Ketika itu, kami sekumpulan jurutera muda di FGV Sabah sedang bersiap sedia untuk menduduki peperiksaan Steam Engineer di Kota Kinabalu.

Dalam ramai-ramai, ada seorang insan yang sangat berbeza — orangnya tenang, tapi bila bercakap pasal boiler, semangatnya menyala macam api dalam relau.
Kami panggil dia “Dukun Boiler.”

Setiap malam, kami akan berkumpul di biliknya — buat study group kecil sambil meneliti buku-buku teknikal yang dia muat turun dari 4Shared.com, satu sumber ilmu yang waktu itu jadi “perpustakaan digital” kami semua.

Kalau lapar, kami turun ke kedai mamak sebelah Megah D’Aru, berhadapan Wisma Perkeso KK. Di situ, sambil hirup teh tarik, kami ulangkaji formula, kira tekanan stim, dan kongsi nota.
Tak sangka, rupanya perjumpaan itu jadi titik mula satu perjalanan panjang yang mengubah arah hidup aku.

Senior MRSM KT dan Semangat yang Tak Pernah Luntur

Borak punya borak, baru aku tahu — si Dukun ni senior aku di MRSM Kuala Terengganu. Dunia kecil rupanya. Tapi yang besar, ialah jiwanya.
Dia bukan sekadar pelajar pandai, tapi inspirator yang menyebarkan semangat belajar dan berjuang.

Belum pun keputusan Steam Engineer keluar, dia dah mencetuskan idea baru:

> “Eh, kita ambik pulak Internal Combustion Engine Engineer Grade 2. Sementara tunggu cooling period untuk Gred 1.”

Cadangan itu nampak gila waktu tu — baru habis satu peperiksaan, nak teruskan dengan satu lagi. Tapi begitulah Dukun. Bila dia bercakap, ada semangat yang sukar nak tolak.

Langkah Demi Langkah – Dari Stim ke Enjin

Balik ke kilang, aku terus hantar permohonan untuk exam ICE Gred 2.
Dan begitulah perjalanan kami — berlari dari satu peperiksaan ke satu lagi.

Kali terakhir kami bersua ialah masa exam Steam Engineer Gred 1.
Lepas itu, jalan kami berpisah. Aku berpindah ke Miri, Sarawak.
Tapi nasihat dan saranan dia tetap aku genggam erat.

Dengan semangat yang dia tanam dulu, aku teruskan perjuangan —
dan akhirnya lulus ICE Gred 1 pada tahun 2011.

Perjalanan Ilmu Tak Pernah Berhenti

Bila siri peperiksaan jurutera stim selesai, aku terasa kekosongan.
Macam ada ruang yang masih perlu diisi.

Lalu aku teruskan langkah — join ISP (Incorporated Society of Planters), ambil LISP Level 1 & 2, dan kemudian sambung MBA di OUM.

Waktu pandemik Covid-19 tahun 2019, aku tekad daftar PhD di KUIS (kini Universiti Islam Selangor).
Namun, takdir membawa aku ke Lahad Datu untuk projek baru — dan pengajian itu terhenti seketika.
Tapi semangatnya belum padam.

Terhutang Budi Pada Seorang Dukun

Kadang-kadang dalam hidup, kita tak sedar siapa yang jadi penyuluh jalan.
Bukan dengan kata-kata manis, tapi dengan semangat dan teladan.

Bagi aku, insan itu ialah Dukun Boiler.
Dia bukan sekadar rakan belajar — tapi pemangkin perjalanan hidup.

Kerana dia, aku belajar bahawa:

> Ilmu bukan untuk lulus peperiksaan, tapi untuk menyalakan semangat belajar sepanjang hayat.

Hari ini, bila aku menoleh ke belakang, aku sedar —
setiap malam di kedai mamak, setiap buku yang kami baca, setiap exam yang kami ambil,
semuanya membentuk siapa aku hari ini.

Dan kalau ada satu perkara yang aku mahu orang muda faham,
ialah kejayaan bukan milik orang bijak, tapi milik mereka yang tak berhenti mencuba.

“Dukun Boiler” bukan sekadar nama.

Ia adalah simbol —
bahawa di balik asap dan tekanan stim,
ada insan yang menyalakan api ilmu,
dan semangat itu, tak pernah padam.

#dukunboiler #msiea #steamengineer #boiler #sawit #mrsm #usm #ukm #sabah #malaysia