Accord Boiler Safety Program – Info Pack for Factories & Brands

August 2019

Following a decision by the Accord Steering Committee, boiler safety will be integrated in the Accord’s
safety inspection and remediation programs from the last quarter of 2019 onwards. This means that
Accord-covered factories will be inspected for boiler safety and a Boiler Corrective Action Plan will be
developed to monitor remediation of any boiler safety hazards identified. The decision by the Accord
Steering Committee to launch a separate boiler safety program was in response to the findings of a
Pilot Boiler Safety Program conducted between September-December 2018. An overview of the
findings is available on the Accord’s website.

This pack contains information about each step of the inspection process, detailing the conditions for
safe boiler use and maintainance, the different parts of the Accord’s boiler inspection procedure, and
the information that is collected during these inspections.

TABLE OF CONTENTS
• Boiler Safety Inspection Procedures
• Key Boiler Safety Requirements
• Template Test Report Internal Inspection / Hydrostatic Pressure Test
• Template Test Report External Inspection and Functional Test

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 1. BOILER SAFETY INSPECTION PROCEDURES

In order to facilitate the inspection process of the boiler installation Factories shall assist in the
following:

Pre- Inspection Information & Process:

• Provide full technical details of the Boiler installation/s
• Provide approved service drawings of complete installations inclusive of water reticulation
system
• Provide Test & Commissioning Certificates and Maintenance Contracts and logs inclusive of
repairs and replacements and certification for remedial works from approved companies
• In preparation for the initial inspection drain down the boiler, isolate all fuel sources and take
all necessary precautionary measures to ensure equipment, building and human safety
• Arrange for Technical support to be provided on the day of the inspection from the
appropriate factory engineers, maintenance personal and any other representatives familiar
with the operation and maintenance of the systems
• Any other pertinent information relative to the systems

Inspection Procedure:
The inspection procedure shall be separated into two parts: Part 1 - Initial inspection and Part 2 -
Operational Inspection.

Part 1: Initial Inspection:

This shall be carried out whilst the Boiler is fully drained and not operational and shall consist of
a visual inspection that includes, but is not limited to, the following observations and tests:
• Physical gathering of Boiler data from the installation identification plates
• External and Internal visual Inspection and condition assessment inclusive of defect
identification
• Overall assessment of installation configuration, supply and output pipework, valves, etc
• Assessment of Safety monitoring systems, devices, etc
• Assessment of fuel source, water treatment, water/steam side & flue gas side
• Hydrostatic Pressure Test
• Necessary calculations of test pressures where required

Once this process of Part 1 has been completed and the system is found to be in a satisfactory and safe
condition, instruction shall be given to proceed with refilling the system and being made operational
in order to progress to Part 2. This process shall be carried out where possible on the same day in
order to conclude the inspection, unless the capacity of the boiler determines that this is not feasible
within the working day. In that case the Part 2 Operational Test shall be scheduled and the factory
notified accordingly of the new date.

Part 2: Operational Inspection

Once the system is operational and functioning as normal the inspection shall commence noting, but
not limited to, the following:
• External visual Inspection noting operating condition
• Operational monitoring systems: readings on water/steam side: gauges, temperatures, water
level indicators, etc
• Boiler protection systems and operational controls
• Water Pump assessment
• Devices for firing the system and burner assessment
• Functional Test
• Identification and measurements

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Once this process of Part 2 has been completed and the system is found to be in a satisfactory and safe
condition, instruction shall be given to proceed with operations as normal.

Completion of Safety Inspection:

Upon satisfactory completion of the Part 1 & 2 Inspection and Testing a brief overview shall be
conducted with the relevant factory representatives in order to ensure all relevant information has
been received in order to complete the preparation of the reports and CAPs.

Notes:
1. Two complete inspections shall be scheduled per day unless the boiler capacity
dictates otherwise, whereupon Part 2 Operational Inspection shall be re-
scheduled, and the factory notified accordingly of the new date.

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 2. KEY BOILER SAFETY REQUIREMENTS

This document outlines the conditions for safely operating and maintaining boilers at RMG factories.

General Information:

1. Boiler Name Plate should be installed

2. Documentation, including drawings, specifications (technical data) P&ID, wiring diagram for
the cabinet, boiler log book, operation and maintenance manual, flue gas analyses report and
water treatment report should be available.

3. The low water level indicator should be installed.

4. A water treatment station is to be used. the waters must comply with the manufacturer's or
the international boiler water specifications.

5. The pressure gauge must show twice the working pressure. The maximum pressure should be
marked with a red mark and working pressure should be marked by blue mark.

6. A certificated boiler operator must be provided to run the boiler.

7. Boiler and it’s accessories foundation should be as per boiler manufacturing drawing and all
foundation bolts, nuts and washer according to boiler design.

8. Boiler movement should be monitor and to be indicated according to the boiler movement
diagram.

9. All hanger support as properly marked initial and working condition (i.e cold and hot working
condition of the boiler)

10. Boiler registration no. should be marked for each boiler for identification.

11. All pressure and temperature gauges are in visible direction to the boiler operator or proper
provision to be made to see the pressure gauge.

12. Boiler surroundings/room should always be clean and free from any stored goods, waste
materials and combustible materials.

13. Safety valve manual operating lever should be available and always in line with operation.

14. The Boiler and or Boiler room shall be separated by a minimum spatial distance of 3m(10ft)
from all other occupancies where externally located or enclosed in a non-combustible
enclosure of minimum 1 hour’s fire resistance.

15. The Boiler shall be in accordance with the Boiler Act 1923 and all appropriate legislation.

16. Before commissioning of the boiler, a certificate of compliance shall be obtained from the
Chief Inspector of Boilers and a copy provided.

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Conditions in the boiler room.

1. Access is restricted to authorized persons.

2. An emergency stop button should be installed at the boiler and outside near the entrance
door.

3. Emergency exit must be present and marked.

4. Adequate lighting and emergency lighting must be available.

5. There must be an air intake for combustion air (except for electric boilers).
If there is a ventilation system, the air intake must be opposite the exhaust outlet.

6. The chimney must be stable.

7. Existing oil or gas pipes must be regularly checked for leaks.

8. Proper insulation should be required for all hot surfaces (steam line, boilers).

9. Emergency alarm should be required (horn and lighting)

10. Safety valve outlet pipe should be projected/vented outlet of boiler room.

11. Adequate signage regards Hazardous Equipment must be displayed.

12. Adequate provision for Fire Detection & Alarm and suitable Suppression System must be
installed in accordance with standards inclusive of portable extinguishers.

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Test Report Internal Inspection / Hydrostatic Pressure Test of a steam boiler plant

Factory: ………………………………………………………….. Accord ID: ………………………………………….

Inspector(s): ………………………………………………..… Date of inspection: …………………………….

Boiler Data:

Boiler manufacturer: Serial no. / Year of

manufacturing:

Standard: ☐ Shell boiler

☐ Once through water tube boiler
Mfg.-Surveillance by:
☐ ……………
☐ Steam Generator
☐ Hot Water Generator Allowable Pressure: bar/ Mpa / kg/cm2

Steam- / Hot water kg/h / kW Allowable °C / F

capacity: Temperature:
Volume: l Supervision by ☐ Permanent
operator? ☐ Non-permanent up
to ….. hours
Fuel: ☐ Heating oil EL Feed Water ☐ Rev. Osmosis
☐ Natural gas Treatment: ☐ Desoftening
☐………………………. …………………….
Risk of polluted ☐ No
condensate? ☐ Oil/grease
☐ Hardness, lye, salt
water

The boiler was not in operation during the tests.

☐ Internal Inspection

☐ The relevant components on the water-/steam side were inspected by entering the boiler through a
manhole.

☐ The inspection openings only allowed a visual inspection on a random basis.

☐ The test did not result in any specific complaints. The visual inspection on the water side and on
the fire-/ flue gas side did not show any relevant defects. There is no relevant scale on the heating
surfaces.

☐ ……………………………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………………

www.bangladeshaccord.org

These boiler safety inspection guide sheets have been developed by

the Accord as a resource for boiler safety engineers and boiler safety
technicians performing boiler inspections in RMG factories.
☐ Hydrostatic Pressure Test

Test pressure: bar / kg/cm²

☐ Test pressure acc. manufacturer’s plate / Documentation
☐ Additional strength calculation ☐1,5 x P ☐…………………….

☐ The test did not result in any specific complaints. The boiler was tight. No relevant deformations
could be observed.

☐ ……………………..

Defects and measures:

☐ None
☐ ………………………………

Comments:

Result:
☐ There are no objections against further operation.
☐ The defects shall be repaired.
☐ The operation of the boiler cannot be recommended before repair of the defects, no. ………….

Place, Date:

Signature
Name of inspector:

www.bangladeshaccord.org

These boiler safety inspection guide sheets have been developed by

the Accord as a resource for boiler safety engineers and boiler safety
technicians performing boiler inspections in RMG factories.
Test Report External Inspection and Functional Test of a steam boiler plant

Factory: ………………………………………………………….. Accord ID: ………………………………………….

Inspector(s): ………………………………………………..… Date of inspection: …………………………….

Boiler Data:

Boiler manufacturer: Serial no. / Year of

manufacturing:

Standard: ☐ Shell boiler

☐ Once through water tube boiler
Mfg.-Surveillance by:
☐ ……………
☐ Steam Generator
☐ Hot Water Generator Allowable Pressure: bar/ Mpa / kg/cm2

Steam- / Hot water kg/h / kW Allowable °C / F

capacity: Temperature:
Volume: l Supervision by ☐ Permanent
operator? ☐ Non-permanent up
to ….. hours
Fuel: ☐ Heating oil EL Feed Water ☐ Rev. Osmosis
☐ Natural gas Treatment: ☐ Desoftening
☐………………………. …………………….
Risk of polluted ☐ No
condensate? ☐ Oil/grease
☐ Hardness, lye, salt
water

The boiler was in operation during the tests.

☐ External Inspection

Devices on Water/Steam side

Description Certification Set value / Sealed Applicable No.

no. Range

Safety valve ☐ ☐

Water level ☐
limiters (LL)

Water level ☐
limiters (HL)

Pressure limiter ☐ ☐

Temperature ☐ ☐
limiter

www.bangladeshaccord.org

These boiler safety inspection guide sheets have been developed by

the Accord as a resource for boiler safety engineers and boiler safety
technicians performing boiler inspections in RMG factories.
 Pressure gauge ☐

Water level ☐
indication

Condensate - - ☐
surveillance
(water
pollution)

Make-up water ☐
surveillance

Boiler water ☐
surveillance
(conductivity)

Boiler Protection System

☐ Safety Chain hard wired

☐ Failsafe logic
☐ Operational control (not acceptable!)
☐ No information available

Feed water pumps:

Capacity Pressure Applicable
Pump 1 ☐
Pump 2 ☐

☐ Quick shut-down possible (Oil/Gas fired boiler)

☐ 2 Feed water pumps with diverse power supply
☐ Confirmation about harmless behaviour at black-out
☐ ………………………………………………………………………….

Devices of firing system:

Burner: ……………………………………………………………………………………………………..

Burner Management System: ………………………………………………………………………

Description Certification Set value / Sealed Applicable No.

no. Range
Flame Monitoring ☐
Combustion Air ☐ ☐
Pressure limiter
min.
Fuel Pressure ☐ ☐
limiter max.
Fuel Pressure ☐ ☐
limiter min.

www.bangladeshaccord.org

These boiler safety inspection guide sheets have been developed by

the Accord as a resource for boiler safety engineers and boiler safety
technicians performing boiler inspections in RMG factories.
 Tightness control ☐
(Gas)
☐
☐

Purging:………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………

Firing capacity / Max. fuel flow: ……………………………………………………………………………………………………

☐ Functional Test

☐ Safety Valve blow-off ☐ by liftening ☐ by rising the pressure to the set point
☐ Water level limiter ☐ Pressure limiter ☐ Temperature limiter
☐ Flame monitoring at start / during operation
☐ Purging
☐ Others: …………………………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………………………………………..

☐ The test did not result in any specific complaints.

☐ …………………………………………………………………………………………………………………………………

Defects and measures:

☐ None
☐ ………………………………

Comments:

Result:
☐ There are no objections against further operation.
☐ The defects shall be repaired.
☐ The operation of the boiler cannot be recommended before repair of the defects, no. ………….

Place, Date:

Signature
Name of inspector:

www.bangladeshaccord.org

These boiler safety inspection guide sheets have been developed by

the Accord as a resource for boiler safety engineers and boiler safety
technicians performing boiler inspections in RMG factories.