Current Issues on Dangerous

Machineries : Boiler, Unfired

Pressure Vessel and Lifts
By:
Mohd Zahari Hitam
Industrial Safety Devision,
Dosh Malaysia
 Safety Policy Reg.1995
Occupational CIMAH Reg,1996
Safety and Health
SH Committee Reg, 1996
Act, 1994 (Act
514) CPL Reg. 1997
SHO Reg 1997

LEGISLATION

Elec. Passenger and

Factories and Good Lift Reg.1970
Machinery Act, Steam Boiler and UPV
1967 (Act 139) Reg. 1970
 Boiler & UPV Issues:
Hydrostatic Test for In
service boiler
Used boiler & UPV DOSH
requirement
New hydrostatic exemption
procedure
Design approval for used
Autoclave and Air Receiver
Tank at Government Agency
 Hydrostatic test for In Service Boiler
FMA (Act 139)
FMA(Steam Boiler and UPV) Reg. 72(3) dan 72(4)
1.5 x ASWP every 7 years or After Modification/ repair
Hydrostatic test pressure must be according to the
applicable code
Minimum holding time is twenty minutes
Not fully practices by
industry or enforcer.
DOSH Directive to follow
makers standard code
as a guidance.
 ASME Requirement:
ASME Section. 1 : Power Boiler.
Pre-Service
1.5 x MAWP
Stress <= 0.9 yield strength
Water temperature >= 21oC (70oF)
In Service
No specific clause in ASME Sec. 1
ASME PCC-2 (Post Construction Codes)
HT= 1.3 x P x Sat/Sdt
Sat = allowable stress at test temp
Sdt = allowable stress at design temp
NBIC (National Board Inspection Code)
To perform hydrostatic test every 3 years
After boiler repair
Required NDT inspection after 5 years and
subsequent 6 year
Pt.2 Sec. 6: Hydrostatic Test pressure:
Between MAWP and 1.25 x MAWP*

* MAWP : Calculated Maximum Working Pressure

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 Others Standard Codes
BS2790, BS1113, PD5500, TRD, IBR
For Design and Fabrication.
No specific clause or requirement to
perform hydrostatic test during
inservice.
Need to comply with FMA
Requirement

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 Used Boiler & UPV
Discussion with Design Section Head
Re-engineering Process
To re-calculate based on original standard code at the
actual thickness.
Convert the material stress to the equivalent material
accepted by codes.
Perform NDT test to indentify any defect at material
surface, weldment joint, nozzle and others pressure parts.
Inspecting authorities redraw or review the drawing,
calculation and NDT report.
Manufacturer Data Report (if applicable)
Previous maintenance history
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Hydrostatic Exemption Integrated with
Design Approval
Application Letter for HT exemption from
owner
Waiver can be considered based on
technical reason such as:
i. Full RT and strict production control
ii. Cryogenic vessels or refrigerant vessels
iii. Vacuum jacketed vessels
iv. Oil medium
v. Medium cannot mixed with water
(100% dry air)
vi. Skip mounted vessel
vii. others
Hydrostatic Exemption Integrated with
Design Approval
Current Flow Process Integration

i. Apply design approval i. Apply design approval and

(30 days) exemption letter (30 days)
i. Received design approval and ii. DOSH Review and discussion
made payment (2 days) on exemption HT application
ii. Request for exemption from iii. Received design approval letter
HT and submit application for including exemption HT
consideration (30 days) iv. Conduct Pneumatic/Running
iii. Discussion and presentation (if Test
necessary)
iv. Received approval letter for
exemption HT
v. Conduct Pneumatic/Running
Test
 Design Approval for Used Pressure Vessel
in Government Agency
For Autoclave and Air Compressor belong
to Government Agency
Minimum document required:
i. Model and Brand name
ii. Manufacturer name
iii. Year manufacturing
iv. Design pressure, volume
v. Photo and sketch drawing
Search SKUD record, if similar model
found, approval letter will issued
If no data, DOSH inspector will visit site
for re-engineering process
Re-calculate based on actual thickness
measurement by DOSH
Sketch Drawing, NDT report, Approval
Inspecting and testing
 Nameplate

Not adequate information by makers

Regulation 55, FMA (Act 139)
- minimal design data for the UPV
the manufactures or makers
name and address
serial number
design pressure
design code
hydrostatic test pressure
test date
 Lift Issues:
Implementation on Standard
Mandatory
Ratio CP lif 300:1
Additional Safety
Requirements;
EBOPS
Car Locking Device
Skirt Deflector for Escalator
ACCIDENT STATISTIC FOR LIFT DAN ESCALATOR
(BY STATE) YEAR 2011

2011
2 1 1
6 13
2011
8
14 16
KL Johor Selangor
Lif Penumpang
Penang Melaka Perak
Eskalator
Lift Accidents
Escalator Accidents
 Standard Mandatory
To apply Malaysian Standard (MS2021) as a
minimum requirement for lift products.
To ensure the quality of the lift products are
parallel to international standard (EN81.1)
Safety component for lift was inspected and
certified by Accreditation and Certification
Body (CE, MRA, TUV, Sirim)
Certify the performance of the lift (system
test)
 Standard Mandatory
Implementation date:
Ist Stage Standard Mandatory for Safety
Components by 01 Julai 2012
2nd Stage Standard Mandatory for Lift
System and its Components adalah pada 01
Januari 2013
Mandatory for MRL and New Conventional
Lift Type
 Implementation Procedure:
Certification for the whole lift
system test by Inspecting Body
Safety Components certificate from
Mutual Recognisation
Accreditation Body (MRA ILAC,
IPAF, NESTEC,CNAS)
MRL to obtain Model Approval
before to be consider unit
installation
 Certification Body
Means a inspection agency recognised and
accredited by Standard Malaysia.
Lift Institute (CEN) and TUV Notified Body are
most common certification body.
 Safety Components for lift
1. Landing door locking devices
2. Safety gear
3. Overspeed governors
4. Buffers
5. Safety circuits containing electronic components
6. Ascending car overspeed protection means
7. Rupture valve for hydraulic lift
8. One-way restrictor where mechanical moving parts
are used (hydraulic lift)
 Standard mandatory requirement for lift
Safety Components
Testing procedure are based on:
1.MS2021-1:2006 (Safety Rule for the
Construction and Installation of Lifts Part 1:
Electric Lifts)
2.MS2021-2:2007 (Safety Rule for the
Construction and Installation of Lifts Part 2:
Hydraulic Lifts)
Refer to Annex F MS2021-1:2006
3. MS2021-1:2006 >>>MS EN81.1: 2012
 Number of Competent person
Guidelines Sistem Gred Orang Yang Kompeten (OYK)
Lif dan penetapan Nisbah Bilangan Lif Bagi Seorang
OYK Lif.
To ensure the ratio of lift maintained by companies are
adequate enough with the number of lift and skilled
technicians (OYK) available
The lift companies are capable to carry out inspection
and maintenance work accordingly
The ratio 300:1 are based on DOSH study
Every 300 lifts under his supervision is required to have
at least one full Gred OYK
Has implemented mid 2011.
 Grade CP
Categories OYK
Grade I and Grade II
Initial Inspection and annual /regular
inspection
Only Grade I can prepare and sign the 1st
Schedule

Grade III
Regular inspection only
EBOPS (Emergency Batteries Operated
Power Supply)
DOSH directive JKKP IS 127/8/1-klt. 22(76)
To ensure the ventilation and lighting during
mantrap
Malfunction building power supply or problem to
supply electric to the lift.
To power one unit florescent tube 36W in the car
for 2 hours duration.
To avoid panic situation
Date to comply: 1 Jan 2013
 CAR LOCKING DEVICE (CLD)
DOSH Directive JKKP IS 127/8/1-klt. 22(76)
Accident cases statistic indicate increasing trend of
passenger trying to force open car and landing door for
self rescue during mantrap.
Victim lose balance and fall to lift pit.
To avoid passenger force open car door. Rescue team
will do rescue within time
Neighbourhood country (Singapore and Hong Kong)
already implement CLD
Singapore- CLD are compulsory for all SHD.
Implementation: Sept 2012 (new lift) and Jan 2013 for
existing lift.
 Type of CLD
i. Mechanical lock
a locking device which in an
unlocked state enables
opening of the lift door and
operated in mechanical
only
ii. Electromechanical lock
This device is used for the
final locking and unlocking of
the door which is located on
each floor of the building that
the lift is installed
 Car Locking
Device

Ebops Systems
 CHECKLIST FOR INSPECTION OF ELECTRIC PASSENGER AND GOODS LIFT

DEPARTMENT OF OCCUPATIONAL SAFETY AND HEALTH, MALAYSIA

Refer to www.dosh.gov.my
f) Car door locking device
i) Prevent trapped passenger from self rescue Yes No NA

g) EBOPS (Emergency Battery Operated Power Supply)

i) Car lighting _______________ hr(s) Yes No NA
ii) Car ventilation fan __________ hr(s) Yes No NA
 Skirt Deflector
DOSH Directive to implement before Feb 2012
Additional features to escalator to avoid children toe
caught between skirt panel and moving steps
Many cases had happened with soft shoes
Skirt Deflector will avoid gap between skirt panel and
steps (4mm).
Yellow demarcation line will guide
user to stand at right position
2 type skirt deflector (EN115:2008
Clause 5.5.3.4):
Brush type
PVC type
Escalator deflector
 SEKIAN
TERIMAKASIH