1/9/2018 Boiler Safety Guidelines

Boiler Safety - Courtesy of Rentech Boilers

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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

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

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

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Low atomizing air or steam pressure
Wet steam during atomizing.
Worn or damaged atomizer (sprayer plate).
Gas line leaks.
Gas relief valve or atmospheric vent discharge.
Gas line repair.
Wet gas.
Significant change in BTU rating of gas.
High gas pressure
Steam Leaks
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.
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Boiler Safety Guidelines
Supply line valves inoperative or not fully open. Poor atomization. Dirty or smoky fires.
Improper control valve setting. Low supply Discharge of unburned oil in furnace. Fireside
pressure. Explosion. explosion or puff. Fire. Boiler damage. Property
damage. Loss of life and/or injury to personnel.
Steam wet from source. Steam line not Poor atomization. Dirty or smoky fires.
insulated. Steam traps not working. Explosion. 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.
Abrasive material in oil. Normal wear. Leaving Fire. Incomplete or smoky combustion. Flare
out of service burner tip hot furnace. Explosion. back.
Gas Firing
Excessive pressure. Improperly assembled Explosion. Fire. Asphyxiation.
joints. Damage to piping, valves and fittings
carrying fuel. Leaking gasket.
Excessive pressure. Diaphragm rupture in Normal vent discharge.
regulators.
Damaged piping or valves Explosion. Fire. Loss of life or injury. Property
damage.
Presence of distillate in gas Flameout and re-ignition. Explosion. Fire. Loss
of life or injury. Boiler and property damage.
Multiple gas sources with different heating Poor combustion. Explosion. Fire. Boiler or
values. property damage. Loss of life or injury.
Defective gas pressure regulator Fuel rich mixture. Fireside explosion. Fire. Loss
of injury. Boiler or property damage.
Steam Leaks
Damaged or corroded pipes and/or other Sever burns.
pressure parts
Hot Fly Ash
Severe burns to legs and other parts of the Warnings to all personnel concerning this danger. Allow sufficient cooling time before walking
body coming into contact with the hot fly ash. on fly ash. Remove the hot fly ash with caution and suitable equipment. Do not spray water on
Overloading support systems causing failure. hot fly ash. Probe temperature of fly ash before walking on it.
Steam Explosion
Insulate all steam lines. Check proper trap
operation periodically. Follow manufacturer's
instructions.
Insulate all steam lines. Check proper trap
operation periodically. Follow manufacturer's
instructions.
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.
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.
Follow NFPA 54 for wet gas supply system.
Appropriate alarms. Use combustion controls
that compensate for BTU changes.
Monitor for regulator operation. Check
operation and setting of pressure switch
periodically. Repair or replace defective
regulators and switches.
Keep all joints and pipes tight. Warn personnel
of hazards of invisibility of superheated steam
leaks.
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Defective safety valves.
Defective steam pressure gauges.
Low water level.
Scaled or corroded boiler internal surfaces.
Bypassed controls.
Tampering with Controls
Poor maintenance.
Condensate tank explosion.
Inadequate pilot/igniter.
Delayed ignition.
Insufficient combustion air.
Tampering with combustion safety control.
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Boiler Safety Guidelines
Obstruction between boiler and valve. Valve
damaged or corroded (internal). Lever tied
down. Obstruction on valve outlet.
Broken gauge. Gauge is not in calibration.
Blockage in line from boiler to gauge. Gauge
cock is closed. Multiple gauges not in
agreement.
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.
Poor maintenance procedures. Inadequate
inspection. Improper chemical cleaning.
Contaminated boiler water. Poor feedwater
control. Improper water treatment.
Defective electrical wiring. Tampering with
controls and electrical wiring.
Deliberate action by personnel. Lack of
knowledge on the part of the personnel.
Inadequate training.
No definite maintenance policy and procedure.
Lack of interest of the boiler owner. Poorly or operating efficiency. Eventually high repair and procedure. Assign maintenance responsibility.
inadequately trained personnel. No one
assigned the maintenance responsibility.
Improperly vented tank. Vent too small. Vent is
trapped. Frozen condensate in trapped vent.
Furnace Explosion
Low gas pressure. Low oil pressure. Improperly
positioned. Too small nozzle. Plugged orifice.
Improper light-off damper setting.
Inadequate pilot/igniter. Low fuel pressure.
Insufficient fuel rate. Excessive air rate. Low oil
temperature. Water in fuel.
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.
Deliberate action by personnel. Lack of
knowledge on the part of personnel.
Inadequate operator training.
Will not lift to release excess pressure. Impose Replace or repair safety valve. Remove
excess pressure on the boiler. Rupture the obstructions. Periodically test valve per ASME
boiler. Cause loss of life and/or injury to code.
personnel. Cause property damage.
Gauge is not showing the correct pressure. Calibrate gauge regularly. Replace defective
Boiler may be under excessive pressure. gauges. Inspect gauge connection and piping
Prevents operator from being aware of true to boiler for blockage and/or closed cock.
operating conditions.
Overheated boiler surfaces. Ruptured boiler. Verify operation of boiler water feed system
Loss of life and/or injury to personnel. Property periodically. Prove low water cutoff operation
damage. 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).
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.
Controls will not function. Boiler may rupture. Verify proper operation of controls periodically.
May cause furnace explosion. Loss of life. Correct electrical wiring defects immediately.
Property damage. Do not tamper with controls.
Improper operation of boiler. Boiler may Read and follow manufacturer's instructions.
rupture. May cause furnace explosion. Loss of Prevent access by unauthorized personnel by
life. Property damage. locking equipment cabinet. Properly train
operators.
Danger to personnel and property. Low Establish a definite maintenance policy and
replacement costs. Poor operation. Insist on performance of maintenance
functions. Keep maintenance log.
Tank pressure may exceed design pressure. Eliminate traps in vent line. Eliminate
Tank may explode. Loss of life. Property restrictions in vent line. Vent to be full size (no
damage. valves). Vent to be run vertically from tank.
May not ignite the main flame. Delayed Periodic pilot maintenance. Properly position
ignition. Fireside explosion. Fire. Boiler pilot, periodic pilot verification test. Use
damage. Loss of life and/or personal injury. procedures of NFPA 85 series.
Property damage.
Fireside explosion. Fire. Boiler damage. Loss Provide adequate pilot. Correct light-off fuel/air
of life and/or injury to personnel. Property ration setting. Avoid excessive restart attempts.
damage. Review and follow manufacturer's instructions.
Conduct pilot turndown test.
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 inlets
damage. Increased emissions. and outlets, combustion controls boiler gas
passages, hot flue gas passages, hot flue gas
temperature.
fireside explosion. Fire. Loss of life and/or Review and follow manufacturer's instructions.
injury to personnel. Boiler damage. Property Prevent access by unauthorized personnel by
damage. locking equipment cabinets. Train operators in
proper maintenance procedure.
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Manual operation of combustion safety
controls.
Leaking fuel safety shutoff valves.
Excessive negative pressure.
Equipment being serviced or repaired.
Unexpected starting of remotely controlled
equipment. Movement of equipment. Release
of electrical energy. Release of fluid pressure.
Activities related to cleaning.
Entering a confined or enclosed space
(includes but not limited to furnace, drums,
shell, gas passes, ducts, flues, bunkers,
hoppers, tanks).
Oxygen deficiency
Airborne contaminants I.e. gases, vapors,
fumes, dust, and mist.
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Boiler Safety Guidelines
Deliberate action by personnel.
Defective valve. Foreign matter under valve
seat.
Implosions
Flame out. Induced draft fan runaway.
Maintenance
Equipment not locked out, not tagged out, not
placed in zero mechanical state, or not placed
in zero energy state.
Failure to observe safety procedures applicable
to maintenance cleaning.
Extremely hazardous environment I.e. toxic or
inflammable oxygen deficient atmosphere, hot
material, darkness. Temporary internal access
provisions.
Confined or enclosed spaces
Leakage. Inadequate ventilation or exhaust.
May cause ignition of main flame at the wrong
time. Fireside explosion. Loss of life or injury to
personnel. Boiler damage. Property damage.
Fire.
Fuel flows to the boiler. Uncontrolled ignition of Monitor valves for proper operation periodically.
fuel. Fireside explosion. Loss of life and/or
injury to personnel. Boiler damage. Property
damage. Fire.
Equipment damage resulting in personnel
injury.
Physical injury or death.
Potential injury or death to personnel.
Potential danger to life and health.
Potential danger to life or health.
Potential danger to life and health.
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.
Replace defective valves. Leak test and verify
proper operation of valves periodically.
Maintain proper operation of control
equipment. Do not bypass control equipment.
Use procedures of NFPA 85G.
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 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.
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.
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.
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Expose moving equipment
Exposed fan blades.
Exposed moving parts of sootblowers.
Obstructed areas.
Lack of access to equipment.
Accidental opening of the access door.
Exposed energized electrical wiring.
Open electrical boxes.
Opening switch box without turning off power.
Working on energized electrical equipment.
Improper use of tools and lights.
Combustible dust entering the electrical
equipment.
Fire.
Coal supply fire.
Fire at burner deck, fuel stations, or other areas
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Boiler Safety Guidelines
Unexpected Starting of Remotely Controlled Equipment
Guards not installed.
Guards not in place.
Guards not in place.
Poor housekeeping.
Access not provided.
Failure to bolt or lock closed door.
Electrical
Damaged insulation or protective covering.
Failure to cover boxes.
Damaged safety catch permitting opening
without shutting off switch.
Second party closing switch which energizes
equipment.
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.
Not keeping dust proof equipment closed. Poor
housekeeping.
Fire
Explosion. Electrical or mechanical failure.
Improper operation of equipment. Poor
housekeeping.
Spontaneous combustion.
Electrical or mechanical component failure.
Bodily injury. Dismemberment.
Bodily injury. Dismemberment.
Injured or lost fingers. Bodily harm.
Potential injury to personnel.
Potential injury to personnel.
Potential injury to personnel.
Electrical shock resulting in death, injury, or
burns.
Electrical shock resulting in death, injury or
burns.
Electrical shock resulting in death, injury or
burns.
Electrical shock resulting in death, injury or
burns.
Electrical shock resulting in death, injury or
burns.
Death, injury or burns. Equipment damage.
Explosion and/or fire.
Potential injury or death to personnel. Potential
equipment or property damage.
Potential injury or death to personnel. Potential Operate in accordance with the manufacturers
equipment or property damage.
Potential injury or death to personnel. Potential
Reinstall guards. Avoid loose clothes. Confine
long hair.
Reinstall guards.
Reinstall guards. Avoid loose clothing. Confine
long hair.
Provide a safe means of access to all
equipment and working places. Maintain all
access ways in a clean safe condition.
Provide a safe means of access to all
equipment and working places.
Bolt or lock all access doors.
Use care to prevent damaging insulation.
Repair damaged insulation.
Cover boxes. Instruct personnel to keep boxes
covered.
Repair safety catch. Turn off switch before
opening box. Don't tamper with interlocks.
Follow lockout and tagout procedures.
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.
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.
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.
Operate equipment in accordance with
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adjacent to the boiler.
Wet steam during atomizing.
Worn or damaged atomizer. (sprayer plate.)
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Boiler Safety Guidelines
Fuel leaks. equipment or property damage.
Steam wet from source. Steam line not Poor atomization. Dirty or smoky fires.
insulated. Steam traps not working. Explosion. 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.
Abrasive material in oil. Normal wear. Leaving Fire. Incomplete or smoky combustion. Flare
out of service burner tip in hot furnace. Tip back.
abuse. Explosion.
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.
Insulate all steam lines. Check proper trap
operation periodically. Follow manufacturer's
instructions.
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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