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Boiler & Pressure Vessel

Safety

To Provide Guidance for the Safe


Operation and Maintenance of Pressure
Vessels.

Prepd By : P K Kurmi, GET 04-05 1


External Inspection
Leaks: Chemical control, excessive make-up rate,
increase corrosion rates.
Indicating devices: Gages & glass,
thermometer.
Safety Devices: Cutoffs, low water level alarms,
burner failure alarms and safety valves. Label - of last test
date & pressure rating.

Control System: Kept clean and free moving


no external electrical safety hazards.

Prepd By : P K Kurmi 2
External Inspection (Continued)
Valves: Clean and free from leakage.
Housekeeping: Kept clear of
combustible materials. Oil, grease and or
chemicals.
Signs: All accesses to boiler rooms are to
be labeled High Noise Area Hearing
Protection required.
Piping Supports: Positive support
ensure no shifting or loose support brackets.

Prepd By : P K Kurmi 3
General Test Procedures

Safety / Relief Valve Operational Test (Document Monthly) All safety valves are to be tested in
place each month by using the test level provided. With boiler pressure at least 75% of safety valve set
point, fully open the Safety / Relief Valve and let it snap shut. If the valve does not reseat properly, repeat
the test. If the Safety / Relief valve cannot be lifted, the boiler must be shutdown immediately until
the valve can be repaired or replaced. NOTE: Excessive hand lifting will shorten the life of the valve.
Prior to installation in a boiler system, all safety valves shall be inspected, set and tested by a qualified
valve repair shop. The shop should provide documentation of the inspection and methods used to set and
test the safety valve.

Check System for Leaks (Document Weekly) the entire system is to be checked closely for leaks
daily and documented weekly. Particular attention should be paid to pump and valve packing, automatic
air vents, and condensate tank overflow lines. Excessive leaks will result in excessive corrosion & scale
buildup in the boiler and result in shortened boiler life.

Low Water Fuel Cutoff (LWFCO) Rapid Drain Test (Document Weekly & on Startup) With the
burner in operation, rapidly flush the LWFCO chamber using the drain valve provided. The burner must
shut off when the device is drained. If the boiler does not have at least one properly functioning
LWFCO, it must not be left unattended, while operating, until repairs are made. ENSURE VISUAL
AND AUDIBAL ALARMS FUNCTION PROPERLY.

Burner Check (Document Monthly) Observe the boiler and burner for a long enough period to be
certain that the burner operates normally. Test the Combustion Safeguard System.

Prepd By : P K Kurmi 4
General Test Procedures
Water Chemistry Check (Document Monthly) Ensure contracted vender has conducted proper water
chemistry checks and provided support documents. Conduct action recommended on report to maintain
proper chemistry

LWFCO slow Drain Test (Document Quarterly) with the burned in operation, verify the function of
the LWFCO by slowly reducing the level of the water in the boiler. Great care must be taken to prevent
actually firing the boiler with insufficient water.

Condensate Pump Check (Document Quarterly with the LWFCO Test) When conducting the
LWFCO test, verify operation of the condensate pump and / or emergency feeder.

Safety Valve Setpoint Test (Document Annually) Safety and relief valves are to be tested annually to
ensure they are set correctly and are in proper operational condition. Normally this can be accomplished
while he boiler is shutdown for annual internal inspection.

Drain Water Gage Glass (As necessary) Danger: Possibility of escaping hot water / steam can
cause burns. If necessary, to remove suspended or floating impurities, drain and flush the water column
and gages glass by shutting the top and bottom isolation valves of the gage glass then slowly crack open
gage glass drain. Shut gage glass drain after water column has drained. Slowly open upper gage glass
isolation valve then slowly open lower gage glass drain. Water level should immediately rise in the gage
glass.

Prepd By : P K Kurmi 5
Operating Parameters
Boilers operated in the proper ranges will help ensure
the mechanical integrity and life of the unit.
pH: low pH = rust, high pH = causes pitting.
Stack Temperature: Kept between 300 & 400
degrees (depending on boiler load), high temp
indicates efficiency significantly reduced.
Steam Pressure: Should never exceed 150 psi,
except during pressure lift check of safety valves.
Chemicals: Boiler chemicals are caustic, require
PPE, clean-up spills when they happen, review
MSDS before handling, trained personnel only.

Prepd By : P K Kurmi 6
Maintenance
Replacement parts must comply with manufactures proper rating.
Improper materials = explosion or rupture.
Lockout / Tagout, Confined Space Entry, Electrical Safety & Hot Work
Procedures will be followed at all times.
Thermal energy must be dissipated prior to starting work.
Valves: Before making packing adjustments depressurize system.
Pumps: Packing adjustments, pump running, one flat at a time,
leakage minimum 2 drops maximum 6 drops per second. Over
tightening can cause pump shaft sleeve damage.
Gaskets: Always install new gasket material when mechanical joints
have been disassembled. Never reuse old gaskets.

Prepd By : P K Kurmi 7
Pre-Startup & Automatic Shut-down
Checks Match-up
Procedures: Check when ?
1. Prior to firing a boiler? A. Leakage of water, steam,
2. Extended shutdown 12 to 24 fuel.
hours.? B. Wet thermal insulation.
3. Daily Checks? C. Per-start-up check.
4. Automatic Boiler Shutdown? D. Pipe supports alignment
and condition.
E. Clean & free combustible
material.
F. Extended shutdown.
G. Flame Out Shutdown
device.
H. Gages, thermometers.
I. Low Water Level Alarm.

Prepd By : P K Kurmi 8
SOP

Preparations and Safety Precautions for Internal Inspection


Annual internal inspection of pressure vessels by a licensed inspector.
Water level remains at normal operating level until the unit has been
cooled down.
Fast cool down can cause cracking or damage to boiler casing, tubes &
welds.
Ensure safe conditions exist for the inspection.
Confined Space Entry procedures are followed.
Fuel turned off.
Power turned off.
Dont embarrass your self in-front of the OSHA inspector.

Prepd By : P K Kurmi 9
SOP (continued)
Lock & Tagout the fuel supply and ignition systems.
Shut, lock & Tagout all system isolation valves for steam, gas, water
and feed systems.
Draw off all water and thoroughly washout the waterside.
Drain valves or cocks between two closed valves before opening
manholes.
All drains & vent valves must be open.
Alternative lines may be blanked or sections of pipe removed.
Remove manhole and hand-hole plates, washout plugs, inspection
plugs as may be required by the inspector.
Remove grates, insulation / brickwork to determine condition of boiler,
headers, furnace, supports etc
Remove pressure gages for testing, open fireside doors and ventilate
before Confined space Entry.

Prepd By : P K Kurmi 10
Records
Inspection records 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 BSE office and
maintained permanently.
Safety Device Tests / Check records are to be
maintained for one year on most recent basis.
Safety Valve Certification records, provided by a
valve repair shop, maintained on most recent basis.

Prepd By : P K Kurmi 11

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