Boiler 1

1.
2. Knows that Boilers require following GENERIC precautions when starting from cold
condition but consults office for any special ship specific instructions from
manufacturers and follows accordingly:
a. Closed valves – Main steam stop valve, blow down valves and sampling lines.
b. Open valves-gauge glasses, vents, main and aux feed water line.
c. Fills up boiler with good quality distilled water through auxiliary feed line until
water appears approximately 25-50 mm above lowest glass, in lower section of
gauge glass.
c. Closes aux feed line valves while keeping main feed line valves open.
d. Knows that main feed controller and related feed valve operate on pneumatic
signals from DP transmitter and that DP transmitter WILL not work if HP and LP pipes
and associated cells are empty.
e. Ensures control air supply is restored to ALL automatic valves and controllers and
power is switched on as applicable.
f. Knows that DP transmitter must be flushed and primed, according to makers’
instruction manual and KLSM detailed instructions, whereby both LP and HP lines /
cells are sequentially filled with water, and vented, until the reference chamber level
rises to indicate the water level correctly in the remote gauges in ECR and other
locations.
g. Regularly checks that remote and local level readings are the same.
h. Knows the DP transmitter also sends a pneumatic signal to the feed controller and
related control valve for maintaining the boiler water level automatically.
i. Knows to re-confirm that the DP transmitter is sending a representative pneumatic
level signal to the feed controller valve and controlling the automatic feed (filling)
valve accordingly.

j. Knows to further fill boiler to normal level using the main feed line, and selecting
normal working level, according to makers’ specific instructions.
k. Knows that the above steps are required to confirm the normal operation of both
the auxiliary and main feed systems and this MUST be completed before firing the
burners to raise steam.
2. Boiler fuel oil system valves to be opened correctly.
3. Inspects furnace for oil and foreign objects before closing inspection doors.
4. Ventilates boiler thoroughly with FD fan, to purge any gases
5. Re-circulates fuel oil until fuel temperature at burners rises to normal.
6. Reconfirms control air supply is restored to automatic valves and controllers, and
electrical supply is switched on to main panel etc.
7. Confirms Water level is available in water drum by:
a. Recording the cascade tank level before and after filling up boiler to estimate
 quantity filled.
b. Compare both gauge glasses and further compare to remote level gauge for

confirmation.
c. Blow through the gauge glasses according to makers’ procedures and OH.06.29
d. Test low level alarm and low low cut out according to OH.06.08, by reducing level
in test chamber, after isolation.
e. Test low level alarms and low low level trips by actually lowering drum water level,
to ensure pipes and valves are working normally

8. Prepare for ignition as follows:

a. Reset all alarms after power is switched on.
b. Where a differential transmitter DP is installed, confirms operation is according to
makers’ instructions and DP cell signals are restored to normal.
c. Confirm Feed water controller and related valve is working normally and
responding to changing DP transmitter control signals.
d. Where a pump start / stop method is installed, confirms satisfactory operation,
with declining and rising levels signals function to start and stop feed pump
accordingly.
e. Selects manual mode to start FD fan and pre-purges furnace for at least five
minutes.
f. After purging, selects LOW firing mode (at minimum fuel), to start ignition in auto
or manual mode, according to requirements and KLSM instructions.
g. If burner fails to ignite:
i. Carries out post purging for sufficient time to clear flammable gas from the
furnace.
ii. Identifies root cause and troubleshoots according to maker's instructions manual
before attempting to restart.
h. Does not make repeated failed attempts to ignite boiler without finding the fault.
i. Knows to stay well clear of flame path of backfire, to avoid personal injury.

1. Knowledge of MARPOL Annex I (Oil) and applicability to ships.

a. Able to understand and implement rules regarding handling Sludge, oil and bilge water
on-board and recording in Oil record Book according to applicable MEPC circulars.
2. Knowledge of Annex IV (SEWAGE) and applicability to ships.
3. Knowledge of Annex V (GARBAGE) and applicability to ships.
a. Ability to implement rules and handle engine room garbage in accordance with garbage
management plan.
4. Knowledge of MARPOL Annex VI (AIR) regulations and applicability to ships as follows:
a. Ozone depleting substances
b. Nitrogen oxides and ability to maintain Engine Parameter Record Book (NOx file) in
accordance with MARPOL regulations.
c. Volatile organic compounds.
d. Sulphur oxides as follows:
 i. Knowledge of applicable CARB area rules.
ii. Knowledge of applicable ECA area rules.
5. Shipboard incineration according to MARPOL Regulations.
6. Understand definition of special areas according to IMO and applicable rules in special
areas, under Annex I, V and VI.
7. Knowledge of VGP rules for USA with application and implementation on ships.

Knowledge of MARPOL Annex VI related to Sulphur Oxides and applicability to ships

operations as follows:
a. Present maximum sulphur content is 1% for any fuel oil used within an Emission Control
Area ECA. Bunker Delivery Notes to be checked for compliance.
b. Must complete change over to compliant fuel prior entry into ECA areas. Must be able to
estimate fuel consumption and volume to be replaced in pipelines etc.
c. Knows that there must be written procedures available on-board on method of
changeover, with valve details etc.
d. Changes over from SECA compliant low-sulphur fuel only AFTER departure from SECA
area.
e. At each changeover to record quantities of ECA compliant fuel oil on-board (ROB), with
date, time and position of ship when either completing change over prior to entry or
commencing changeover after exit from ECA.
f. The above records to be made in a logbook according to Flag state, or in absence of
specific instructions, in ORB Annex I, which is also KLQSMS procedure. (Note: Panama flag
ships prescribe mandatory Annex VI part III B entries)
2. Ensures that ECA compliant fuel remains segregated from higher sulphur fuels in
designated Low sulphur tanks.
3. Follows KLSM guidelines and ship specific forms to maintain above records.
4. Knowledge of CARB rules for USA coast, applicable within prescribed distance from land,
where all fuel oil consumption must be changed over to Low sulphur Diesel oil for
compliance,

5. Knows present rules applicable to all European ECA area ports, regarding 0.1% LSDO use.
Rules require complete changeover of running diesel generators to Low sulphur Diesel oil as
soon as possible after arrival and from it as late as possible prior to departure unless the
vessel stay is less than 2 hours duration.
6. Aware of Risks during changeover and of operation of Main Engine on DO, with possible
risk of damage to fuel system components, due to low lubricity of DO, at elevated
temperatures. Knows how to regulate DO temperature by DO coolers, where retrofitted.
7. Knows the risk of uncontrolled rapid changeover subjecting fuel system components to
fast temperature variation, and consequent thermal stress and takes steps to mitigate by
gradual controlled changeover.
Boiler 2

1. Knows that Boilers require the stated GENERIC precautions, when starting from cold
condition, according to OH.06.15
2. Knows heating method and time required differs between smoke and water tube boilers,
due to slower method of heat diffusion in Smoke tube boilers, and takes adequate steps
accordingly.
3. Knows these GENERIC steps for water tube boilers, but follows KLSM and makers specific
instructions:
a. To prevent excessive thermal stress, fire only for short periods of a few minutes (1-2
minutes) interspersed with 1-hour intervals to allow heat to diffuse throughout the boiler
water and metal structure.
b. Knows to estimate by feeling and touching various distant parts of boiler metal casing, to
assess the rate of heat diffusion
c. Knows it is safer to spend a longer period, than to force the boiler with consequent
exposure to thermal stress.
4. Knows that for smoke tube boilers the rate of heat diffusion is less and these need a
much longer interval of several hours ( 4-6 hours), between firings periods of 1-2 minutes, to
allow even heating and seeks and follows ship specific makers’ and KLSM specific advice on
duration of firing and stoppage intervals.
5. Knows to follow above method of intermittent firing until steam emits from the vent
valves and air is excluded completely, only then closes vent valves.
6. Raises steam pressure further by gradual intermittent firing method stated above,
according to makers’ specific procedures and office instructions.
7. Knows that several hours (up to more than one day) may be required to bring boiler into
service and plans accordingly in consultation with office.

8. Confirms pressure gauge function by blowing through to clear the steam pipeline to
gauges.
9. Confirms water level again to be satisfactory, by blowing gauge glasses, and comparing
readings between gauges, for confirmation.
10. Rotates burners, where multiple burners available, to allow brickwork to heat up
evenly.
11. Warms up steam lines if small warm up lines are provided, or by cracking open the main
steam stop valve.
12. Knows the risk of water hammer and takes steps to drain system lines and sections
accordingly.
13. Knows to ensure steam traps function correctly, to avoid water hammer.
14. Knows that the water must be maintained at LOWER safe level, due to the expansion
and increase in volume when the water is heated up, with the risk of carryover.
15. Knows not to rely on automation alone and ensures safety by personal supervision, and
organises watch-keeping accordingly when raising steam.
Boiler 3

1. Knows that, with the exception of exhaust gas boiler safety valves, which can only be
tested when underway, and producing steam, safety valves must only be adjusted
and set in the presence of a surveyor.
2. Can disassemble, present for examination by surveyor, and re-assemble safety
valves. Knows KLSM arranges shore assistance for this work and assists accordingly.
3. Checks when the valve is overhauled that it can lift by at least d/4, where 'd' is the
diameter of steam passage covered by the valve.
4. Checks that the drain lines are clear
5. Ensures that calibrated gauges (usually two to ensure accuracy) are connected to
the boiler shell
6. Knows that, for maximum thermal efficiency, safety valves should normally be set
to the maximum working pressure of the boiler. Where there are separate super
heater and saturated steam safety valve, the super heater safety valves are normally
set slightly lower so that they will lift first and maintain steam flow through the
super heater to prevent possible overheating.
7. Knows that under test, a small allowance of 3% of maximum working pressure is
made for the maximum pressure at which the valves must lift under test.
8. Knows how to gag one of the two safety valves at each test so that the other one
can be checked and set.
9. Switches the boiler to manual firing so that burner does not cut out for high steam
pressure and monitors boiler pressure carefully during the test.

10. Aware of the risk of scalding if the valve is open during adjustment, and knows
that boiler pressure should be lowered, before valve spring tension is adjusted, and
then raised again for test.
11. Can attend with surveyor, check and if necessary adjust lifting pressure to
surveyor's requirements. Measures the distance between compression ring and
valve body, and fits spacer rings according to this measurement. Ensures that
adjustment is secured, easing gear refitted, cover refitted and sealed off.
12. Knows that surveyors usually require to re-witness lifting of both valves once
operational condition has been restored.
13. Checks that high-pressure trip is operational and correctly set on completion of
test.
14. Records the value of opening pressure in the Engine logbook and obtains a
signed copy from the Classification Surveyor for the vessels records.
1. Knows that exhaust gas boiler safety valves can only be tested when underway and
producing steam, and therefore Chief Engineer can act in place of the Classification
Society surveyor.
2. Checks when the valve is overhauled that it can lift by at least d/4, where 'd' is the
diameter of steam passage covered by the valve.
3. Checks that the drain lines are clear
4. Ensures that calibrated gauges (usually two to ensure accuracy) are connected to
the boiler shell
5. Knows that safety valve setting pressure is normally decided by Class and should
be similar to previous set pressure.
6. Ensures that main engine is operating above at least 50% power so that exhaust
gas boiler is generating steam
7. Knows that one of the two safety valves must be gagged so that the other one can
be tested.
8. Can close in exhaust gas boiler outlet valve and raise pressure in the boiler to set
pressure
9. If the valve does not lift at the correct pressure, can reduce the boiler pressure
before adjusting spring tension
10. Measures the distance between compression ring and valve body, and fits spacer
rings according to this measurement. Ensures that adjustment is secured, easing
gear refitted, cover refitted and sealed off.
11. Knows to re-witness lifting of both valves once operational condition has been
restored.
12. Records the value of opening pressure in the Engine log book and prepares a
statement for the Classification Surveyor, to include:
a. Identification number of the vessel
b. Identification number of the valve adjusted
c. Date of adjustment
d. Opening pressure of the valve
e. Closing pressure of the valve
f. That manual operation using the easing gear was carried out
g. Chief Engineer's name and signature
1. Knows PID controller (3-term controller) has following:
a. P control with adjustable P band gain to obtain stability, and initially high offset unless
narrow P band (high gain) is used.
b. Reset I action to compensate for offset.
c. Rate D action to speed up valve movement when rapid load changes occur.
2. Knows controllers are set up during commissioning and need adjustments only when
experiencing control issues, e.g., hunting or offset etc., that cannot be resolved by following
makers’ troubleshooting instructions, e.g., cleaning of orifices, checking for leaks, dirt
ingress etc..
3. Knows that the basis of PID controller adjustment is to obtain the narrowest P band
(highest gain) possible to obtain a good response but without being so narrow (high gain)
that it introduces the risk of instability (hunting).
4. Knows that controllers should be set for most difficult conditions, which are typically
lower loads during manoeuvring.
5. Knows the basic steps followed when adjusting a PID controller are to:
a. Adjust reset dial to max. (Usually 20 mins.) (Reset action becomes very slow).
b. Adjust rate dial to minimum (usually 0.05 mins) means no rate action.
c. Adjust P dial (usually 250% to 10%), to reduce P band widthwhile checking for hunting.
When it hunts in certain P band, STOP and set to optimum value usually 2 to 4 times this
value.
d. Gradually reduce reset time dial until hunting begins, then reverse a little and lock it.
e. Set rate dial to about 1/4th of final reset time.
f. Confirm satisfactory operation by observing behaviour under changing load conditions
g. Knows that in PI controllers can omit above step number 5.5.