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Boiler Safety - Courtesy of Rentech Boilers back to Banks Engineering Boiler page
Safety Manual
General This documentation does not replace the Owners existing company safety operating procedures and instructions. All normal safety precautions should be followed when operating boilers, burners, and fuel systems. Consult the Owners plant operating and safety authorities for complete details. In addition to the categorized hazards shown in the various sections of this manual, there are general type categories, which need emphasis: Manufacturer's Instructions - Equipment manufacturer's instructions should be followed. Training - Employees must be trained in safety prior to operation of the equipment. The training in safety should be a continuous process for the purpose of educating employees to recognize and to keep safety in their minds throughout their careers. A training program should be established and maintained. Housekeeping - Good housekeeping is essential for safety and good plant operation. Poor housekeeping results in increased safety hazards. A clean and orderly environment will foster safety. Clothing and Protective Equipment - Proper clothing should be worn at all times. Avoid loose clothing and jewelry. Protective equipment must be worn when necessary (i.e.: hard hats, respirators, ear plugs, goggles, gloves, safety shoes, etc.). Never operate rotating equipment, mechanically automated devices, or electrically and pneumatically operated control components unless guides, shields, or covers are in place. Hot Surfaces - Many hot surfaces exist in a boiler area and even non-heated surfaces can become uncomfortably warm, therefore, employees, especially new employees, must be made aware of these conditions. Refractory and insulation are typically provided to encounter elevated surface temperatures in some installations. Care must be exercised to prevent burns and other thermal hazards when near the boiler. Never enter the boiler until an adequate cool-off period has been observed and the Owner's entry procedures have been completed. Lockout and Tagout Procedures - Every plant should have a formalized lockout and tagout procedure that is strictly enforced. Remote Starting of Equipment - Much of the equipment in plants are started remotely and/or automatically without warning; therefore, employees must be alert to avoiding that equipment which can be started remotely. If work is to be done on any equipment, lockout and tagout procedures must be followed. Attach signs to equipment such as "DO NOT START - MEN AT WORK". Attach a similar sign on the equipment control panel. Unexpected Noise - A sudden and/or unexpected noise may cause employees to move involuntary. Such reaction may result in injury. Precautions against this are hard to take out but experience probably is the best teacher to prevent such inadvertent responses. Unconventional Fuels - Sometimes unconventional fuels need to be burned in boilers. When this is done, particular attention should be paid to the hazards that can result. Theses may from characteristics in the fuels, toxic chemicals in the fuel, and toxic chemicals produced through combustion. Persons knowledgeable in the use of such unconventional fuels should be consulted concerning the problems that may be encountered. Because of the wide variety and limited use, such fuels are not addressed in this manual. Fire and Explosion Hazards - A fired boiler utilizes fuels which are flammable and potentially explosive. Extreme care should be exercised when making fuel-piping connections. Use the correct gasket, bolts, thread lubricants, and tightening torque to prevent leaks. It is recommended that drain valve and/or vent piping be channeled to safe locations. Valve packing should be periodically tightened and a rigorous leak check program be implemented as part of the Owners preventative maintenance program. Electrical Hazards - Potentially hazardous voltages exist in control cabinets and electrically actuated control components. These components should only be serviced when system power is removed and only by qualified electrical or instrumentation servicemen. Operating Hazard Cause Effect Prevention
Oil Firing
Low fuel temperature (on equipment burning Faulty and/or fouled heater element. Oil Poor atomization. Dirty or smoky fire. Check oil temperature periodically. Check
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fuel oil, which requires heating prior to combustion.)
Improper Thermostat setting. Steam control Poor atomization. Oil gasification. Unstable valve stuck open (steam heater). Electrical flame. Fireside explosion or puff. Fire. Boiler supply contacts welded closed (electrical damage. Property damage. Loss of life heater). Explosion. and/or personnel
Supply line valves inoperative or not fully open. Improper control valve setting. Low supply pressure. Explosion.
Poor atomization. Dirty or smoky fires. Discharge of unburned oil in furnace. Fireside explosion or puff. Fire. Boiler damage. Property damage. Loss of life and/or injury to personnel.
Insulate all steam lines. Check proper trap operation periodically. Follow manufacturer's instructions.
Steam wet from source. Steam line not insulated. Steam traps not working. Explosion.
Poor atomization. Dirty or smoky fires. Sparkles in flame. Discharge of unburned oil in furnace. Fireside explosion or puff. Fire. Boiler damage. Property damage. Loss of life and/or injury of personnel.
Insulate all steam lines. Check proper trap operation periodically. Follow manufacturer's instructions.
Abrasive material in oil. Normal wear. Fire. Incomplete or smoky combustion. Flare Check tips regularly. Use copper tools to Leaving out of service burner tip hot furnace. back. clean tips. Follow manufacturer's Explosion. instructions. Replace gaskets when cleaning or replacing tips. Do not use copper tools for cleaning stainless steel parts.
Gas Firing
Gas line leaks. Excessive pressure. Improperly assembled joints. Damage to piping, valves and fittings carrying fuel. Leaking gasket. Explosion. Fire. Asphyxiation. Color code piping. Adequate ventilation. Keep all piping, valves and fittings in good repair. Test for leaks before placing equipment in operation. Avoidance of use of pipes for supporting other equipment or walking on. Warning personnel o hazards so they will report leaks promptly. Insure safety devices are operative.
Explosion. Fire. Loss of life or injury. Property damage. Pipe all relief valves and vents to point of safe discharge.
Use accepted methods for purging and recharging gas lines. Follow NFPA 54.
Wet gas.
Flameout and re-ignition. Explosion. Fire. Loss of life or injury. Boiler and property damage.
Poor combustion. Explosion. Fire. Boiler or Appropriate alarms. Use combustion controls property damage. Loss of life or injury. that compensate for BTU changes.
Fuel rich mixture. Fireside explosion. Fire. Loss of injury. Boiler or property damage.
Monitor for regulator operation. Check operation and setting of pressure switch periodically. Repair or replace defective regulators and switches.
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Steam Leaks
Steam Leaks Damaged or corroded pipes and/or other pressure parts Sever burns. Keep all joints and pipes tight. Warn personnel of hazards of invisibility of superheated steam leaks.
Steam Explosion
Defective safety valves. Obstruction between boiler and valve. Valve Will not lift to release excess pressure. damaged or corroded (internal). Lever tied Impose excess pressure on the boiler. down. Obstruction on valve outlet. Rupture the boiler. Cause loss of life and/or injury to personnel. Cause property damage. Replace or repair safety valve. Remove obstructions. Periodically test valve per ASME code.
Broken gauge. Gauge is not in calibration. Gauge is not showing the correct pressure. Blockage in line from boiler to gauge. Boiler may be under excessive pressure. Gauge cock is closed. Multiple gauges not in Prevents operator from being aware of true agreement. operating conditions.
Calibrate gauge regularly. Replace defective gauges. Inspect gauge connection and piping to boiler for blockage and/or closed cock.
Defective low water cutoff. Low water cutoff Overheated boiler surfaces. Ruptured boiler. Verify operation of boiler water feed system bypassed. Improper water column blowdown Loss of life and/or injury to personnel. periodically. Prove low water cutoff procedure. Equalizing lines restricted or Property damage. operation periodically. Use proper water plugged. Tampering with low water control. column blow down procedures. Train boiler Defective boiler water feed system. Operator operators. Do not tamper with low water error. Defective or inoperative gauge glass. controls. Replace defective low water controls. Inspect equalizing line (especially the lower line).
Poor maintenance procedures. Inadequate inspection. Improper chemical cleaning. Contaminated boiler water. Poor feedwater control. Improper water treatment.
Ruptured boiler. Loss of life and/or injury to Proper maintenance. Regular inspections by personnel. Property damage. Boiler competent inspector. Keep inspection log. overheating. Proper boiler water treatment.
Bypassed controls.
Controls will not function. Boiler may Verify proper operation of controls rupture. May cause furnace explosion. Loss periodically. Correct electrical wiring defects of life. Property damage. immediately. Do not tamper with controls.
Deliberate action by personnel. Lack of knowledge on the part of the personnel. Inadequate training.
Improper operation of boiler. Boiler may Read and follow manufacturer's instructions. rupture. May cause furnace explosion. Loss Prevent access by unauthorized personnel of life. Property damage. by locking equipment cabinet. Properly train operators.
Poor maintenance.
No definite maintenance policy and procedure. Lack of interest of the boiler owner. Poorly or inadequately trained personnel. No one assigned the maintenance responsibility.
Danger to personnel and property. Low Establish a definite maintenance policy and operating efficiency. Eventually high repair procedure. Assign maintenance and replacement costs. Poor operation. responsibility. Insist on performance of maintenance functions. Keep maintenance log.
Improperly vented tank. Vent too small. Vent Tank pressure may exceed design pressure. is trapped. Frozen condensate in trapped Tank may explode. Loss of life. Property vent. damage.
Eliminate traps in vent line. Eliminate restrictions in vent line. Vent to be full size (no valves). Vent to be run vertically from tank.
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Furnace Explosion
Inadequate pilot/igniter. Low gas pressure. Low oil pressure. Improperly positioned. Too small nozzle. Plugged orifice. Improper light-off damper setting. May not ignite the main flame. Delayed Periodic pilot maintenance. Properly ignition. Fireside explosion. Fire. Boiler position pilot, periodic pilot verification test. damage. Loss of life and/or personal injury. Use procedures of NFPA 85 series. Property damage.
Delayed ignition.
Inadequate pilot/igniter. Low fuel pressure. Insufficient fuel rate. Excessive air rate. Low oil temperature. Water in fuel.
Fireside explosion. Fire. Boiler damage. Loss of life and/or injury to personnel. Property damage.
Provide adequate pilot. Correct light-off fuel/air ration setting. Avoid excessive restart attempts. Review and follow manufacturer's instructions. Conduct pilot turndown test.
Lack of or insufficient boiler room air openings. Dirty combustion air blower. Combustion air blower running too slow or slipping. Incorrect fuel/air ration setting. Blower inlet blockage. Outlet damper blockage. Plugged boiler gas passage.
Poor combustion. Delayed ignition. Fireside Provide adequate air to boiler room. Keep explosion. Loss of life and/or injury to combustion air fans clean and run at proper personnel. Property damage. Fire. Boiler speed. Periodically observe dampers, air damage. Increased emissions. inlets and outlets, combustion controls boiler gas passages, hot flue gas passages, hot flue gas temperature.
Deliberate action by personnel. Lack of knowledge on the part of personnel. Inadequate operator training.
fireside explosion. Fire. Loss of life and/or Review and follow manufacturer's injury to personnel. Boiler damage. Property instructions. Prevent access by unauthorized damage. personnel by locking equipment cabinets. Train operators in proper maintenance procedure.
May cause ignition of main flame at the wrong time. Fireside explosion. Loss of life or injury to personnel. Boiler damage. Property damage. Fire.
Do not operate combustion safety control manually. Review and follow manufacturer's instructions. Provide adequate training for operators. Prevent access of unauthorized personnel by locking equipment cabinets.
Fuel flows to the boiler. Uncontrolled ignition of fuel. Fireside explosion. Loss of life and/or injury to personnel. Boiler damage. Property damage. Fire.
Monitor valves for proper operation periodically. Replace defective valves. Leak test and verify proper operation of valves periodically.
Implosions
Excessive negative pressure. Flame out. Induced draft fan runaway. Equipment damage resulting in personnel injury. Maintain proper operation of control equipment. Do not bypass control equipment. Use procedures of NFPA 85G.
Maintenance
Equipment being serviced or repaired. Equipment not locked out, not tagged out, Unexpected starting of remotely controlled not placed in zero mechanical state, or not equipment. Movement of equipment. placed in zero energy state. Release of electrical energy. Release of fluid pressure. Physical injury or death. Place the equipment if zero energy state or zero mechanical state. Establish and comply with lockout and tagout procedures. Train and alert personnel. Warning signs. Use blocking devices or ties to prevent movement of equipment.
Observe operating and maintenance instructions for maintenance cleaning. Observe all safety regulations and normal
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Entering a confined or enclosed space (includes but not limited to furnace, drums, shell, gas passes, ducts, flues, bunkers, hoppers, tanks).
Extremely hazardous environment I.e. toxic or inflammable oxygen deficient atmosphere, hot material, darkness. Temporary internal access provisions.
Observe all safety regulations and normal safety precautions. Provide sufficient ventilation to assure fresh air quality and quantity to maintain the health and safety of personnel. Test for oxygen deficiency with field type oxygen analyzers or other suitable devices. Develop stand-by emergency plans and procedures. Report all unsafe conditions and/or unsafe practices. Work with a partner. Test for toxic or flammable gas. Provide lights before entering a confined space.
Oxygen deficiency
Provide sufficient ventilation to assure fresh air quality and quantity to maintain the health and safety of personnel. Wear approved respiratory protective equipment. Test for oxygen deficiency with field type oxygen analyzers or other suitable devices. Observe all safety regulations and normal precautions. Report all unsafe conditions and/or unsafe practices.
Operate ventilation and exhaust systems. Wear approved respiratory protective equipment. Wear protective clothing. Observe all safety regulations and normal safety precautions. Report all unsafe conditions and/or unsafe practices.
Reinstall guards.
Obstructed areas.
Poor housekeeping.
Provide a safe means of access to all equipment and working places. Maintain all access ways in a clean safe condition.
Electrical
Exposed energized electrical wiring. Damaged insulation or protective covering. Electrical shock resulting in death, injury, or burns. Use care to prevent damaging insulation. Repair damaged insulation.
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Repair safety catch. Turn off switch before opening box. Don't tamper with interlocks.
Working on energized electrical equipment. Second party closing switch which energizes Electrical shock resulting in death, injury or equipment. burns.
Lack of grounding. Cut off group prong. Using two wire extension cords. Not grounding "cheater" plug (adapter plug). Body contact with wet surface. Damaged insulation. Using lights without guards.
Don't cut off ground prong. Use only 3-wire heavy-duty extension cords properly grounded. Ground "cheater" plug if used. Use double insulated portable tools. Use low voltage trouble lights or battery operated lights. Make sue guard is installed on light.
Keep dust proof equipment closed. Practice good housekeeping procedures. Insure proper operation of purge equipment.
Fire
Fire. Explosion. Electrical or mechanical failure. Improper operation of equipment. Poor housekeeping. Potential injury or death to personnel. Potential equipment or property damage. Operate equipment in accordance with manufacturers' recommended operating procedures. Conduct routine equipment maintenance. Practice good housekeeping. Report all unsafe conditions and/or practices. Train and drill operators in emergency fire fighting and extinguishing procedures. Use fire protection systems.
Spontaneous combustion.
Operate in accordance with the manufacturers recommended operating procedures. Practice good housekeeping. Report all unsafe conditions and/or unsafe practices. Train and drill operators in emergency fire fighting control and extinguishing procedures. Use fire protection and/or inserting systems. Proper coal supply.
Fire at burner deck, fuel stations, or other areas adjacent to the boiler.
Operate equipment in accordance with manufacturers recommended procedures. Locate fuel, combustible materials, and controls away from boiler surfaces. Report all unsafe conditions and/or practices. Train and drill operators in emergency fire fighting and extinguishing procedures, Use fire protection systems. Repair leaks promptly.
Steam wet from source. Steam line not insulated. Steam traps not working. Explosion.
Poor atomization. Dirty or smoky fires. Sparkles in flame. Discharge of unburned oil in furnace. Fireside explosion or puff. Fire. Boiler damage. Property damage. Loss of life and/or injury to personnel.
Insulate all steam lines. Check proper trap operation periodically. Follow manufacturer's instructions.
Abrasive material in oil. Normal wear. Leaving out of service burner tip in hot furnace. Tip abuse. Explosion.
Check tips regularly. Use copper tools to clean tips. Follow manufacturer's instructions. Replace gaskets when cleaning or replacing tips. Do not use copper tools for cleaning stainless steel parts.
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