Introduction to Power Engineering

Learning Outcome
When you complete this chapter you will be able to
Describe the overall industrial background and certification system for Power
Engineering.
Learning Objectives
Here is what you will be able to do when you complete each objective.
1. Define the terms Power Plant and Power Engineer.
2. Describe the competency certification system.
3. List the national standards that are used in the Power Engineering industry.
Introduction
power plant is many things. !or the purposes of this course it may be considered as any
process for the generation and utili"ation of steam. #t includes steam generators or
boilers$ steam turbines$ electric generators$ motors$ refrigeration and air conditioning
e%uipment$ control systems$ water treatment and fuel handling facilities$ emergency and
stand&by e%uipment$ and environmental protection e%uipment.
power plant provides such output as electric power for light$ and steam heat or cooling
to condition air. 'his output may be used to provide climate control of buildings$ or to
condition air or products in industrial processes.
(any governmental agencies having )urisdiction over construction$ inspection$ and
operation of such plants define the term *power plant* as meaning+
1. ny one or more boilers in which steam or other vapour is generated at more than
1,3 kPa -1. psi/0 or
2. ny one or more boilers containing li%uid and having a working pressure
e1ceeding 11,, kPa -12, psi/$ and a temperature e1ceeding 121
o
3 -2.
o
!/$ or
either one of these0 or
3. ny system or arrangement of boilers referred to in subclause -1/ or -2/0 and the
engines$ turbines$ pressure vessels$ pressure piping system$ machinery$ and
ancillary e%uipment of any kind used in connection therewith.
'he preceding definition applies e%ually to a small portable boiler or to a steam generator
that may be many stories high.
!igure 1. small and large power plant.
Objective One
When you complete this objective you will be able to
Define the terms Power Plant and Power Engineer.
Learning Material
Power Engineering
The Power Engineer
power engineer is a skilled worker who operates and maintains the e%uipment in a
power plant. 4n&the&)ob activity covers the entire process of heat generation and heat
utili"ation. #t is usually not necessary to know all design features of all e%uipment$ but in
order to make it function safely and economically one must understand basic design
re%uirements and the limitations involved.
#n a large plant$ the power engineer may function as a supervisor who directs others in
safe and efficient operation on a shift. 'his includes other power engineers operating the
steam generators or boilers$ those in water treatment sections$ and those who operate
turbines$ engines$ pumps and other e%uipment that utili"es heat or energy. 5ork orders
may be issued covering the repair of e%uipment by maintenance staff. 'he Power
Engineer may recommend purchase of depletable supplies$ such as salt$ and may be
totally responsible for one shift or for all shifts.
E%uipment 4perated 6y Power Engineers !igure 2
(a) (b)
(c)
mong other pieces of e%uipment$ a power engineer may be called on to operate a small
turbine -a/$ a large feedwater pump -b/$ or an industrial diesel engine -c/.
#n a smaller plant$ the power engineer may operate and maintain e%uipment$ order
supplies$ and generally assume full responsibility for the entire plant. 'here may be no
other staff.
Historical Development of the ocation
'he power industry has long employed automatic devices for both handling and
controlling fuels and e%uipment. Each new power plant e1hibits more of the
characteristics of automation+ increased mechani"ation$ more fre%uent use of automatic
e%uipment$ and continuous monitoring of processes and costs.
#t is difficult to establish dates when certification of power engineers first began. Long
before the invention of the steam engine$ manual firing of furnaces was under legal
scrutiny. royal proclamation by Edward # of England in 13,2 prohibited the *use of sea
coals in furnaces*$ and established a commission which could rela1 the rules in the case
of careful firemen or fine the more careless. #n 7ermany$ because of pollution problems$
metal plants were scrupulously monitored and sometimes denied the use of coal as early
as 13.,.
'he steam engine$ invented early in the nineteenth century$ gave mankind the first source
of power that was steady and reliable. #t was originally used to remove water from mines
and thus increase productivity. !or many years$ it was the practice for the engines to be
put together on site. 'he mechanics who built an engine were loaned by the builder to
commission and start up the engine$ and often to operate the entire power plant.
!re%uently they stayed with the new owner.
4wners hired unskilled helpers$ who started out doing manual labor$ often on the coal
pile. 'hrough a system that they called *progression*$ these workers were promoted to
)obs with gradually increasing levels of skill as they ac%uired e1perience. s new plants
were built and labour became more mobile$ former employers *certified* the state of
progression of a person moving to a new plant.
#n the trend to greater efficiency$ higher boiler pressures were adopted$ and this led to
serious accidents occurring due to the actions of un%ualified personnel. #t was natural for
insurance underwriters and governments to become involved$ and to take responsibility
for the certification of both operators and e%uipment.
#n recent years there has been a dramatic increase in efficiency in the modern plant. 3lose
control of the steam generation process and enforcement of anti&pollution regulations has
enlarged the responsibility of the power engineer$ demanding more knowledge and
providing greater opportunity to use his or her talent. !or the power engineer who wishes
to achieve )ob satisfaction in this e1panding technology$ the learning process never ends.
!ature of the Wor"
'he government of the province or territory in which an engineer works passes a 6oilers
and Pressure 8essels ct that contains a rule similar to the following+
'he holder of a 3ertificate of 3ompetency$ the classification of which authori"es
him9her to act as an engineer$ may sketch$ construct$ install$ operate$ repair$ and
give advice on all things pertaining to any power plant in which that person is
employed$ but is not entitled to perform any welding unless holding a 3ertificate
of 3ompetency permitting him9her to do so.
'he beginning engineer is most likely to be involved in operation and repair$ until enough
knowledge and e1perience has been gained to perform the other functions outlined in the
Act.
#n very small plants$ much of the work may be manual+ opening and closing valves$
operating pumps$ checking the flame$ starting electric motors$ and determining the time
and operation of water softeners. ll these tasks may be performed by the engineer
working alone.
#n larger plants$ automatic control systems open and close valves and regulate massive
e%uipment that was formerly controlled by hand. 3entral control panels$ as shown in !ig.
3$ and closed circuit television often enable one engineer to operate systems that would
re%uire many operators if operated manually.
'he engineer:s function is that of an interpreter. (ounted on the control panel are the
instruments which display information re%uired to safely control boilers$ generators$
industrial processes$ and air conditioning e%uipment. 4n the basis of that information$
changes are made automatically. 'he engineer analy"es malfunctions and trends
promptly$ and with simple manipulation of knobs and switches commands the plant to
proceed with the desired *steady state* operations.
!igure 3. 3entral control panels.
Wor"ing #onditions
Power engineers can e1pect to have year&round employment without seasonal lay&offs. #n
plants that never shut down$ power engineers can usually e1pect to work eight or twelve
hours per day$ in rotating shifts on week days$ weekends$ and holidays. ;hifts are
arranged so that at some point several days *off* are grouped together in a type of
vacation leave.
common practise in many plants is to operate three shifts$ starting at < a.m.$ = p.m.$ and
12 midnight$ with four groups handling these three shifts. 'he pattern of shift rotation
permitting three working groups and one *off* group$ is essentially a weekly pattern of
seven days$ rather than the usual five days.
'he popular 12&hour shift pattern is a little more complicated. 4ne such schedule is
shown in 'able 1$ involving eight crews plus one relief crew$ indicated by ->/
4n ?anuary 11$ for e1ample$ ;hift @ in the steam plant works the same daytime hours as
;hift 3 in the process plant. 4n ?anuary 12$ ;hift @ in the steam plant works the same
daytime hours as ;hift = in the process plant. 'he same patter is followed for two
consecutive night shifts. 4n ?anuary 1.$ ;hift @ begins five consecutive days off.
'able 1 'ypical 12 Aour ;hift Pattern
'o help promote accident&free performance$ most working areas are clean and well&
lighted. 3entral control rooms are fre%uently air&conditioned.
'he power engineer must reali"e$ however$ that some plant areas may be dirty0 with dust$
fumes$ smoke$ high temperatures$ and high noise levels. 4n occasion$ the engineer may
be re%uired to work in damp or cold areas$ in a crouched or prone position to inspect$
ad)ust$ or repair e%uipment.
6ecause work must be performed close to boilers$ rotating e%uipment$ electrical
e%uipment$ piping$ and plant processes$ the power engineer must guard against burns or
other in)uries that may occur due to faults in e%uipment.
$ethods and Procedures
ll operation$ testing$ and repair re%uires rigid adherence to specific methods and
practices set out and covered under local plant practice and manufacturer:s instructions.
;afety demands that these be followed at all times. 'he power engineer can e1pect to
share in setting up and obeying all such practices$ and to serve as an e1ample to fellow
employees or to those under his or her guidance. sample of general rules employed in a
typical plant follows. (ore specific rules would be formulated for light&up and shut&
down of boilers and care of other specific machines.
%ummary of #are and &peration of the 'oiler
'here are a number of general rules for the care and operation of our boiler. ;ome
of these may seem simple$ but there are many cases on record where boiler
failures have been attributed to neglect in following the most elementary rules of
operation.
>ule
1
Bnow your boiler. E1amine it thoroughly and know the function
and reason for each part.
>ule
2
3heck the fire for stability$ color$ and turbulence as fre%uently as
other duties will permit.
>ule
3
(aintain the water at proper level.
>ule
=
#n case of low water$ bank the fires immediately and allow boiler
to cool slowly.
>ule
.
5hen a boiler is out of service for cleaning$ the water column
connections should be thoroughly cleaned and all scale and mud
removed.
>ule
2
6lowdown the boiler at proper intervals. ;hort blowdowns at
fre%uent intervals are preferred to long ones with more time
between.
>ule
@
Cse soot blowers fre%uently enough to keep boiler heating
surfaces clean. 'he accumulation of soot means loss of efficiency
and decreased capacity due to increase in e1it gas temperatures.
>ule
<
'est safety valves at intervals by increasing the pressure to the
point at which they are supposed to blow. #f the boiler is e%uipped
with a superheater$ be sure that the superheater safety valves blow
first.
>ule
D
'he boiler will be thoroughly cleaned and washed out annually.
6e sure that no large pieces of loose scale are left in the boiler$ as
serious tube trouble is liable to result.
>ule
1,
'he baffles should be e1amined periodically to see that they are
tight and in place.
>ule
11
'he steam gage will be tested for accuracy at least every time the
boiler is down for cleaning.
>ule
12
Each boiler is fitted with an automatic stop&and&check valve on
the steam outlet. 'hese should be checked at regular intervals for
scale accumulation.
>ule
13
4il should be kept out of all boilers and feedwater. 5hen oil is
mi1ed with the soft mud found in a boiler it will bake to a very
hard scale which causes tubes to burn out. 5hen oil is mi1ed with
water$ it causes serious foaming.
Objective Two
When you complete this objective you will be able to
Describe the competency certification system.
Learning Material
Power Engineering #ertificates
(egal )e*uirements
#n the various governmental )urisdictions it is clearly set out in cts or >egulations that$
with few e1ceptions$ a power plant must be operated+
1. Cnder the general supervision of the holder of a 3ertificate of 3ompetency$ the
classification of which %ualifies the holder to act as chief steam engineer of the
power plant$ and
2. Cnder the continuous supervision of the holder of a 3ertificate of 3ompetency$
the classification of which %ualifies the holder to act as shift engineer under the
general supervision of a person referred to in clause -1/.
3ertificate of 3ompetency is a document issued by a legal authority stating that a
power engineer meets certain %ualifications and has passed certain re%uired e1aminations
set up by that authority.
#n lberta$ the Safety Codes Act establishes the following certificates0 other provinces and
territories have established a somewhat similar structure.
1. !irst 3lass Engineer:s 3ertificate of 3ompetency
2. ;econd 3lass Engineer:s 3ertificate of 3ompetency
3. 'hird 3lass Engineer:s 3ertificate of 3ompetency
=. !ourth 3lass Engineer:s 3ertificate of 3ompetency
.. !ireman:s 3ertificate of 3ompetency
2. ;pecial 4il 5ell 4perator:s 3ertificate of 3ompetency
@. Pressure 5elder:s 3ertificate of 3ompetency
<. 6uilding 4perator:s 3ertificate of 3ompetency
D. ;uch other certificates of competency and any grade or class thereof as may be
prescribed in the regulations.
'ypical regulations governing the limitations of certificates may include the following+
E+ample ,- !ourth 3lass Engineer:s 3ertificate of 3ompetency %ualifies the holder to+
a. 'ake charge of the general care and operation of a power plant having a
capacity of not more than 1,,, k5 as chief steam engineer$ and to
supervise the engineers in that plant.
b. 'ake charge of the general care and operation of a power plant consisting
of one or more coil&type drumless boilers having an aggregate capacity not
e1ceeding .,,, k5$ when used for the sole purpose of underground
thermal flooding in oil fields$ as chief steam engineer.
c. 'ake charge of a shift in a power plant having a capacity of not more than
.,,, k5$ as shift engineer.
d. 'ake charge of a shift in a power plant consisting of one or more coil type
drumless boilers having an aggregate capacity of not more than 1, ,,,
k5$ when used for the sole purpose of underground thermal flooding in oil
fields$ as shift engineer.
e. 'ake charge of a section of a power plant having a capacity of not more
than 1, ,,, k5$ as assistant engineer$ under the supervision of the shift
engineer in that plant.
f. 'ake charge of the general care and operation of a power plant having a
capacity of not more than .,,, k5 and operating at a pressure not more
than 1=, kPa.
E+ample .- !irst 3lass Engineer:s 3ertificate of 3ompetency %ualifies the holder to+
a. 'ake charge of the general care and operation of any power plant as chief
steam engineer$ and to supervise the engineers in that plant.
b. 'ake charge of a shift in any power plant as shift engineer.
'he student will find the limitations assigned to other classes of certificates in the local
ct and >egulations.
Progression to a Higher #ertificate
6oth e1perience and educational re%uirements must be met in order to obtain higher
3ertificates of 3ompetency. 4ne must already hold a lower certificate than that of the
class sought$ and in addition must serve a certain number of months in an operating
capacity.
n engineer must progress successively through the various classes. !or e1ample$ it is
not possible to move directly from the !ourth 3lass 3ertificate to the ;econd 3lass
3ertificate0 the candidate must at some time hold a 'hird 3lass 3ertificate.
'he progression route is outlined in the >egulations of each )urisdiction over power
engineers. 5ith such a clear&cut route$ it is anticipated that each student will plan his or
her career so as to reach and en)oy a high level of certification. !irst 3lass Engineer:s
3ertification of 3ompetency is shown in !ig. =.
!igure =. !irst 3lass 3ertificate of 3ompetency

#orrespondence #ourses
3redits in lieu of plant e1perience will be granted on successful completion of a course in
power engineering satisfactory to the chief inspector. ;uccessful completion means that
the student must complete all assignments and pass a final e1amination. #f$ for e1ample$ a
candidate successfully completes such a course for the !ourth 3lass 3ertificate$ an
accredited certificate as shown in !ig. . will be awarded$ entitling that student to an
e1perience credit of si1 months. 3redits are given for completion of appropriate courses
towards all certificates.
'he certificate shown in !ig. . is issued upon successful completion of a correspondence
course.
!igure .. 3ertificate ;uitable !or !raming.
!&TE- 'he certificate issued upon successful completion of this
course is not a Power Engineer:s 3ertificate of
3ompetency.
'his course and the other Power Engineering correspondence courses offered by this
#nstitute are courses satisfactory to the chief inspector. !urthermore$ successful
completion of Part of any one course satisfies the basic educational re%uirements for
the appropriate class of certificate.
'his series of Power Engineering courses constitutes the core or *standard* course for
almost all of 3anada and several C.;. )urisdictions. ;tudents completing this standard
material may$ if re%uired$ obtain credit for its successful completion in other )urisdictions.
Objective Three
When you complete this objective you will be able to
List the national standards that are used in the Power Engineering industry.
Learning Material
!ational %tandards
Why %tandards are !ecessary
(uch of the development of modern industrial plants derives from the production and
adoption of standards for industry and for power engineers. standard is a grade or
level of accomplishment that is considered desirable for the following reasons+
1. #t promotes safety for the public$ the plant owners$ and the operators. ;triving for
safety helps to lower insurance costs as well.
2. #t helps lower operation and maintenance costs. 4ne can appreciate the confusion
that would e1ist if there were no uniform standards for pipe threads and fittings.
3. #t forms the basis of government inspection of plants$ and certification
e1aminations of power engineers.
How %tandards are Prepared
;tandards are issued by national organi"ations. 5ithin these organi"ations$ committees
are established to develop safety codes and standards. 'hese committees are made up of
e1perts from industry$ government$ professions$ and insurance organi"ations.
;ince the committees are generally composed of highly %ualified people$ the codes
prepared are adopted as standards$ and receive nation&wide recognition by legislation.
The %tandards #ouncil of #anada
'he ;tandards 3ouncil of 3anada functions as the national co&ordinating body$ through
which organi"ations concerned with voluntary standardi"ation may operate and cooperate
to recogni"e$ establish and improve standardi"ation in 3anada. 'he following accredited$
standards&writing member organi"ations are considered in the correspondence courses+
1. 'he 3anadian ;tandard ssociation -3;/+ a non&profit$ voluntary membership
association that has produced two codes which affect the power engineer+
a. CSA B51 Code for Construction and Inspection of Boilers and Pressure
Vessels
b. CSA B52 Mecanical !efri"eration Code
2. 'he 3anadian 7as ssociation$ which has produced CSA B1#$.1 Installation
Code for %atural &as Burnin" Appliances and '(uip)ent.
3. Cnderwriters Laboratories of 3anada issues standards and tests products. Products
meeting the standard bear a CL3 label.
The /merican %ociety of $echanical Engineers 0/%$E1
'he ;(E is an organi"ation that has developed e1tensive standards for such e%uipment
as pressure vessels$ piping$ and valves. 'he ;(E code often forms a basis for provincial
boiler and pressure vessels regulations. 'he following sections of the ASM' Boiler and
Pressure Vessel Code are important+
;ection # Power 6oilers
;ection ## (aterial ;pecifications & Part ** !errous
;ection ## (aterial ;pecifications & Part *6* Eonferrous
;ection ## (aterial ;pecifications & Part *3* 5elding (aterials
;ection ### Euclear Power Plant 3omponents & Division 1
;ection ### Euclear Power Plant 3omponents & Division 2
;ection #8 Aeating 6oilers
;ection 8 Eondestructive E1amination
;ection 8# >ecommended >ules for 3are and 4peration of Aeating
6oilers
;ection 8## >ecommended >ules for 3are of Power 6oilers
;ection 8### Pressure 8essels & Division 1
;ection 8### Pressure 8essels & Division 2
;ection #F 5elding Gualifications
/merican !ational %tandards 2nstitute 0/!%21
E;# is similar to the ;tandards 3ouncil of 3anada. 'o a large e1tent$ E;# recogni"es
standards developed by groups such as the Eational !ire Protection ssociation$
merican 7as ssociation$ and the ;(E.
'he following E;# standards are a valuable reference source+
6. 31.1., Power Piping
6. 31.3 Petroleum >efinery Piping
6. 31.. >efrigeration Piping
6. 12.. ;teel Pipe !langes and !langed !ittings
B. 21.1 ;afety >e%uirements for ;torage and Aandling of
nhydrous mmonia
2nsurers3 /dvisory &rgani4ation of #anada 02/&1
#4 is an organi"ation of insurance companies with the purpose of minimi"ing insurance
losses through standardi"ation and inspection.
(ocal )egulations
t the municipal level$ enforcement is usually in the field of building codes$ fire codes$ or
health department regulations. !or e1ample$ such regulations may rule that a cylinder of
hydrogen must not be stored in a boiler room. Local regulations may also specify the
location of fire&fighting e%uipment$ or of escape routes from a plant. s with all the
organi"ations discussed above$ safety is their prime consideration.