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Boiler Safety
John Newquist
Problem
Over hundred of
boiler explosion and
fires in the last ten
years.
These are pressure
vessels.
People assigned to
operate and
maintain the boilers
have little or no
boiler safety training.
Maintenance
Lockout
Startup/Re-ignition
Falls
Carbon Monoxide
Documentation
Take Photos
Interviews Boiler
Maintenance Technician,
Maintenance Supervisor.
Boiler Log
The boiler room log
lists boiler
operation data that
can be used to
increase boiler
safety and
efficiency as well
as identifying a
potential
malfunction.
Warning Signs
All boilers that are required
to have operating
certificates shall have a
manufacturer's
nameplate attached. The
nameplate shall have the
appropriate ASME Code
symbol, the allowable
working pressure, date of
manufacture, and the
minimum relief valve
capacity.
Inspections
Regular service
should be
performed on
schedule and
recorded.
Operating records
and inspection
records should be
reviewed regularly
to ensure
compliance.
Inspection
Water and scale
buildup on floor
indicates the relief
valve might have
been leaking past
seat for some time.
This valve should be
replaced as soon as
possible as it could
scale up and become
inoperative.
Backflow Preventer
Back flow preventer
showing scale buildup
on drain opening.
This indicates the
back flow preventer
needs to be tested for
proper operation.
This device detects if the water level within your boiler has dropped
below the manufacturers recommended level. Should this occur, the
low water cutoff will do just as its name implies. It will cut-off the
burner and shut the boiler down.
Without a properly
functioning low water
cutoff, the burner can
continue to fire allowing
for intense heat to build.
The results can be
catastrophic explosions, fires and the
possibility of severe
injuries to personnel and
property.
This must be a regular
boiler test per the
Manufacturers
guidelines.
Water Level
The Normal
Operating Water
Level (NOWL)
should be
approximately in
the middle of the
gauge glass.
Blowdown
The water column is
blown down first and
then the gauge glass
to remove any
sediment. Water
should enter the gauge
glass quickly when the
gauge glass blowdown
valve is closed.
Another Accident
"The fines reflect the company's failure to establish
procedures for a restart of the recovery boiler without the
power boiler being on-line," said Clyde Payne, OSHA's
area director in Jackson, Miss. "Employees were
exposed to a fire and explosion because the employer
failed to develop written boiler setup and operating
procedures.
23 employees were injured, one fatally.
The willful violation is for failing to start the recovery
boiler without adequate steam and not developing safe
procedures to start up the recovery boiler when the
overhead doors were
primary power boiler is off-line. Several
blown off, and one of
these struck 4 employees,
injuring them.
Boiler Restarting
Many accidents during
this process
Exact Start up
Procedures
Trained Operators
Knowledge of what to do
if there is a problem.
Boiler Fall
Carbon Monoxide
Fly Ash
Fly Ash poses an
engulfment and a burn
hazard.
Develop a cleaning AND
unclogging procedure.
Provided a PPE hazard
analysis 1910.132 (d)
Guard against
mechanical hazards.
Confined Space
Lockout
Follow
1910.146
Employees
vacuum
inside or
conduct
inspections.
Codes
2007 ASME Boiler & Pressure Vessel Code, VII,
Division 1, rules for Construction of Pressure Vessels,
section UG-125 General.
NFPA 85
American Society of Mechanical Engineers (ASME)
Code for Pressure Piping, Standard B31.1 2007 Power
Piping, Appendix IV Corrosion Control for ASME B31.1
Power Piping Systems,
The Future
Some Inspection
Less explosions
More eyes and awareness insurance,
S&H professionals, media, bloggers,
Debate on a standard
More Employer Self-assessment
Further
This was prepared as a collaborative effort several
friends as a preliminary aid for anyone in the inspecting
boilers.
These are just some the issues. A comprehensive job
hazard analysis should be conducted for any task where
someone can get hurt.
This is not an official OSHA publication. Those will be on
the OSHA.gov website.
Newquist.john@dol.gov or johnanewquist@gmail.com is
my email if you see any errors
312-353-5977
I want to thank Janet S. for all their assistance in
answering questions and providing insight to the many
hazards in this sector.