Boiler Safety Program

Purpose

The Boiler Safety Program has been developed from the requirements listed by the American Society of Mechanical Engineers (ASME) and the National Board Inspection Code. This chapter provides guidance for the safe operation and maintenance of pressure boilers. Following this program will also extend the serviceable lifetime of boilers and associated equipment.

Governing Documents

The following publications are used for training, operation, maintenance and testing of all boilers:

• Manufacturer's Technical Manual
• ASME Boiler & Pressure Vessel Code, Section VII, Recommended Guidelines for the Care of Power Boilers
• ASME CSD-1, Controls and Safety Devices For Automatically Fired Boilers

Records

• Inspection records provided by an outside organization are to be maintained on file permanently.
• Repair and Maintenance records are to be maintained on file permanently.
• Weekly/Monthly Boiler Inspection records (self inspection) are to be sent to ________ each month.
• Monthly Chemical Analysis reports, by the chemical supplier, are to be maintained for one year.
• Safety Device Tests/Check records are to be maintained for one year on a most recent basis.
• Safety Valve Certification records, provided by a valve shop, are to be maintained on a most recent basis.

Hazards

Boiler operation hazards include steam/hot water burns, burns from hot equipment, steam explosions, fuel fires and chemical exposure.

Hazard Control

Engineering Controls - engineered boiler safety controls include insulation of hot areas such as piping and boiler components, automatic shutdown devices, automatic fire and fuel controls, relief valves and water level controls,

Administrative Controls - administrative procedures include operator training, chemical control procedures, operating procedures, inspections, audits, water chemistry control and planned maintenance.

External Inspections

External inspections should normally be conducted annually. The inspection should be performed by a certified boiler inspector.

External Inspection Areas:

• Leaks: Leaks cause an excessive make-up rate to the boiler which will cause increased introduction of oxygen and a reduction in oxygen control chemicals. This action will result in higher corrosion rates inside the boiler and an increase in scale and sludge buildup. This effect will, in turn, reduce boiler efficiency requiring a higher fuel consumption. Additionally, the life of the boiler will be significantly reduced. External components are also affected by leaks. Wetted thermal insulation will create an ideal environment for accelerated corrosion of pipes and valves. Failure of these types of components, due to external corrosion, can be severe and with little or no advance warning. For this reason, wetted insulation should not be allowed to exist on any boiler or boiler support system. Discolored insulation indicates current or previous wetting.

• Indicating Devices: All indicating devices such as gages, thermometers, gage glasses, etc. are to be kept in good repair. Devices that are damaged or not reading correctly shall be replaced as soon as possible.

• Safety Devices: All safety devices such as boiler cutoffs, low water level alarms, burner failure alarms and safety valves must be kept free of mechanical and electrical defects. Safety Valves should have no evidence of leakage either from the valve stem, telltales or escape piping. All Safety valves must have a stamped label indicating last test date and pressure rating.

• Control Systems: Fuel control systems must be kept clean and free to move. Electrical controls should not have any external electrical safety hazards

• Valves: All valves are to be free of leakage and be clean to ensure proper operation when required for isolation.

• Housekeeping: All boiler areas should be kept clear of combustible materials. Spills of oil or chemicals should be cleaned up as they occur.

• Signs All accesses to boiler rooms are to be labeled "High Noise Area- Hearing Protection Required" or similar signage.

• Piping Supports All piping requires positive support. A check should be made to ensure there is no shifting or loosing of support brackets

Internal Inspections

Internal inspections should normally be conducted annually. The inspection should be performed by a certified boiler inspector.

Internal Inspection Areas:

• Fire Side inspection points
  • Door gaskets
  • Fire side insulation
  • Tube sheet
  • Tubes
  • Blower
  • Stack

  Water Side inspections points:

  • Tube bundle
  • Scale buildup
  • Condensate feed water tanks
  • Chemistry control systems
  • Level floats

Boiler Tests

The following tests are to be conducted at the frequency noted and logged on the check sheet found at the end of this chapter. All tests are to be conducted in accordance with the list of Governing Documents listed at the beginning of this

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