Boiler Safety Guidelines

Boiler Safety - Courtesy of Rentech Boilers

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 Owner’s 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 fuel oil, which requires heating prior to combustion.)	Faulty and/or fouled heater element. Oil temperature control setting too low. Heater electric power off. Steam supply closed. Explosion.	Poor atomization. Dirty or smoky fire. Discharge of unburned oil in the furnace. Fireside explosion of puff. Fire. Boiler damage. Property damage. Loss of life and/or injury to personnel.	Check oil temperature periodically. Check heaters periodically. Follow manufacturer's instructions.

High fuel temperature	Improper Thermostat setting. Steam control valve stuck open (steam heater). Electrical supply contacts welded closed (electrical heater). Explosion.	Poor atomization. Oil gasification. Unstable flame. Fireside explosion or puff. Fire. Boiler damage. Property damage. Loss of life and/or personnel	Check heaters and controls periodically. Follow manufacturer's instructions.

Low atomizing air or steam pressure	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.

Wet steam during atomizing.	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.

Worn or damaged atomizer (sprayer plate).	Abrasive material in oil. Normal wear. Leaving out of service burner tip hot furnace. Explosion.	Fire. Incomplete or smoky combustion. Flare back.	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.



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.

Gas relief valve or atmospheric vent discharge.	Excessive pressure. Diaphragm rupture in regulators.	Normal vent discharge.	Explosion. Fire. Loss of life or injury. Property damage. Pipe all relief valves and vents to point of safe discharge.

Gas line repair.	Damaged piping or valves	Explosion. Fire. Loss of life or injury. Property damage.	Use accepted methods for purging and recharging gas lines. Follow NFPA 54.

Wet gas.	Presence of distillate in gas	Flameout and re-ignition. Explosion. Fire. Loss of life or injury. Boiler and property damage.	Follow NFPA 54 for wet gas supply system.

Significant change in BTU rating of gas.	Multiple gas sources with different heating values.	Poor combustion. Explosion. Fire. Boiler or property damage. Loss of life or injury.	Appropriate alarms. Use combustion controls that compensate for BTU changes.

High gas pressure	Defective gas pressure regulator	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.

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.

Hot Fly Ash
Hot fly ash accumulations in boiler flues and plenums. Fly ash accumulating in flues and plenums. Personnel stepping in fly ash while still hot. Fly ash may retain heat for a number of weeks. No visible difference between hot and cold fly ash. "Quicksand" action of fly ash when stepped on. Explosive effect of water on hot fly ash.	Severe burns to legs and other parts of the body coming into contact with the hot fly ash. Overloading support systems causing failure.	Warnings to all personnel concerning this danger. Allow sufficient cooling time before walking on fly ash. Remove the hot fly ash with caution and suitable equipment. Do not spray water on hot fly ash. Probe temperature of fly ash before walking on it.

Steam Explosion
Defective safety valves.	Obstruction between boiler and valve. Valve damaged or corroded (internal). Lever tied down. Obstruction on valve outlet.	Will not lift to release excess pressure. Impose excess pressure on the boiler. 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.

Defective steam pressure gauges.	Broken gauge. Gauge is not in calibration. Blockage in line from boiler to gauge. Gauge cock is closed. Multiple gauges not in agreement.	Gauge is not showing the correct pressure. Boiler may be under excessive pressure. Prevents operator from being aware of true operating conditions.	Calibrate gauge regularly. Replace defective gauges. Inspect gauge connection and piping to boiler for blockage and/or closed cock.

Low water level.	Defective low water cutoff. Low water cutoff bypassed. Improper water column blowdown procedure. Equalizing lines restricted or plugged. Tampering with low water control. Defective boiler water feed system. Operator error. Defective or inoperative gauge glass.	Overheated boiler surfaces. Ruptured boiler. Loss of life and/or injury to personnel. Property damage.	Verify operation of boiler water feed system periodically. Prove low water cutoff operation periodically. Use proper water column blow down procedures. Train boiler operators. Do not tamper with low water controls. Replace defective low water controls. Inspect equalizing line (especially the lower line).

Scaled or corroded boiler internal surfaces.	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 personnel. Property damage. Boiler overheating.	Proper maintenance. Regular inspections by competent inspector. Keep inspection log. Proper boiler water treatment.

Bypassed controls.	Defective electrical wiring. Tampering with controls and electrical wiring.	Controls will not function. Boiler may rupture. May cause furnace explosion. Loss of life. Property damage.	Verify proper operation of controls periodically. Correct electrical wiring defects immediately. Do not tamper with controls.

Tampering with Controls	Deliberate action by personnel. Lack of knowledge on the part of the personnel. Inadequate training.	Improper operation of boiler. Boiler may rupture. May cause furnace explosion. Loss of life. Property damage.	Read and follow manufacturer's instructions. Prevent access by unauthorized personnel 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 operating efficiency. Eventually high repair and replacement costs. Poor operation.	Establish a definite maintenance policy and procedure. Assign maintenance responsibility. Insist on performance of maintenance functions. Keep maintenance log.

Condensate tank explosion.	Improperly vented tank. Vent too small. Vent is trapped. Frozen condensate in trapped vent.	Tank pressure may exceed design pressure. Tank may explode. Loss of life. Property 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.

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 ignition. Fireside explosion. Fire. Boiler damage. Loss of life and/or personal injury. Property damage.	Periodic pilot maintenance. Properly position pilot, periodic pilot verification test. Use procedures of NFPA 85 series.

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.

Insufficient combustion air.	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 explosion. Loss of life and/or injury to personnel. Property damage. Fire. Boiler damage. Increased emissions.	Provide adequate air to boiler room. Keep combustion air fans clean and run at proper speed. Periodically observe dampers, air inlets and outlets, combustion controls boiler gas passages, hot flue gas passages, hot flue gas temperature.

Tampering with combustion safety control.	Deliberate action by personnel. Lack of knowledge on the part of personnel. Inadequate operator training.	fireside explosion. Fire. Loss of life and/or injury to personnel. Boiler damage. Property damage.	Review and follow manufacturer's instructions. Prevent access by unauthorized personnel by locking equipment cabinets. Train operators in proper maintenance procedure.

Manual operation of combustion safety controls.	Deliberate action by personnel.	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.

Leaking fuel safety shutoff valves.	Defective valve. Foreign matter under valve seat.	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. Unexpected starting of remotely controlled equipment. Movement of equipment. Release of electrical energy. Release of fluid pressure.	Equipment not locked out, not tagged out, not placed in zero mechanical state, or not placed in zero energy state.	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.

Activities related to cleaning.	Failure to observe safety procedures applicable to maintenance cleaning.	Potential injury or death to personnel.	Observe operating and maintenance instructions for maintenance cleaning. Observe all safety regulations and normal safety precautions. Provide a safe means of access for maintenance cleaning. Provide personnel with protective clothing and equipment. Establish a routine procedure to clean and remove residue (ash, soot, slag) frequently to prevent excessive accumulation. Report all unsafe conditions and/or unsafe practices.

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.	Potential danger to life and health.	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	Confined or enclosed spaces	Potential danger to life or health.	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.

Airborne contaminants I.e. gases, vapors, fumes, dust, and mist.	Leakage. Inadequate ventilation or exhaust.	Potential danger to life and health.	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.

Unexpected Starting of Remotely Controlled Equipment

Expose moving equipment	Guards not installed.	Bodily injury. Dismemberment.	Reinstall guards. Avoid loose clothes. Confine long hair.

Exposed fan blades.	Guards not in place.	Bodily injury. Dismemberment.	Reinstall guards.

Exposed moving parts of sootblowers.	Guards not in place.	Injured or lost fingers. Bodily harm.	Reinstall guards. Avoid loose clothing. Confine long hair.

Obstructed areas.	Poor housekeeping.	Potential injury to personnel.	Provide a safe means of access to all equipment and working places. Maintain all access ways in a clean safe condition.

Lack of access to equipment.	Access not provided.	Potential injury to personnel.	Provide a safe means of access to all equipment and working places.

Accidental opening of the access door.	Failure to bolt or lock closed door.	Potential injury to personnel.	Bolt or lock all access doors.

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.

Open electrical boxes.	Failure to cover boxes.	Electrical shock resulting in death, injury or burns.	Cover boxes. Instruct personnel to keep boxes covered.

Opening switch box without turning off power.	Damaged safety catch permitting opening without shutting off switch.	Electrical shock resulting in death, injury or burns.	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 equipment.	Electrical shock resulting in death, injury or burns.	Follow lockout and tagout procedures.

Improper use of tools and lights.	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.	Electrical shock resulting in death, injury or burns.	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.

Combustible dust entering the electrical equipment.	Not keeping dust proof equipment closed. Poor housekeeping.	Death, injury or burns. Equipment damage. Explosion and/or fire.	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.

Coal supply fire.	Spontaneous combustion.	Potential injury or death to personnel. Potential equipment or property damage.	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.	Electrical or mechanical component failure. Fuel leaks.	Potential injury or death to personnel. Potential equipment or property damage.	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.

Wet steam during atomizing.	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.

Worn or damaged atomizer. (sprayer plate.)	Abrasive material in oil. Normal wear. Leaving out of service burner tip in hot furnace. Tip abuse. Explosion.	Fire. Incomplete or smoky combustion. Flare back.	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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