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OBSERVING BOILER SAFETY RULES
The rules that follow are brief reminders of the possible consequences in a boiler plant ofinappropriate operator response or questionable action in maintaining the boiler plant. In allcases, follow the published or oral safety rules of your employer, jurisdiction, and the FederalOSHA safety regulations to avoid possible disciplinary actions. In addition, study the safetyguidelines of the manufacturer of your boiler.
NEVERALWAYS
NEVER fail to anticipate emergencies. Do notwait until something happens to start thinking.ALWAYS study every conceivable emergencyand know exactly what moves to make.NEVER start work in a strange plant withouttracing every pipeline and learning the locationand purpose of every valve. Know your job.ALWAYS proceed to proper valves or switchesrapidly but without confusion in time ofemergency. You can think better walking thanrunning.NEVER allow sediment to accumulate in gauge-glass or water-column connections. A falsewater level may fool you and make you sorry.ALWAYS blow out each gauge-glass and water-column connection at least once a day.Forming good habits may mean longer life foryou.NEVER give verbal orders for importantoperations or report such operations verballywith no record. Have something to back you upwhen needed.ALWAYS accompany orders for importantoperations with a written memorandum. Use alogbook to record every important fact orunusual occurrence.NEVER light a fire under a boiler without adouble check on the water level. Many boilershave been ruined and many jobs lost this way.ALWAYS have at least one gauge of waterbefore lighting off. The level should be checkedwith the gauge cocks. You will not be fired forbeing too careful.NEVER light a fire under a boiler withoutchecking all valves. Why take a chance?ALWAYS be sure blow down valves are closedand proper vents, water-column valves, andpressure-gauge cock are open.NEVER open a value under pressure quickly.The sudden change in pressure, or resultingwater hammer may cause piping failure.ALWAYS use the bypass if one is provided.Crack the valve from its seat slightly and awaitpressure equalization. Then open it slowly.NEVER cut a boiler in on the line unless itspressure is within a few pounds of headerpressure. Sudden stressing of a boiler underpressure is dangerous.ALWAYS watch the steam gauge closely andbe prepared to cut the boiler in, opening thestop valve only when the pressures are nearlyequal.NEVER bring a boiler up to pressure withouttrying the safety valve. A boiler with its safetyvalve stuck is nearly as safe as playing withdynamite.ALWAYS lift the valve from its seat by the handlever when the pressure reaches about three-quarters of popping pressure.NEVER take it for granted that the safety valvesare in proper condition. The power plant is noplace for guesswork.ALWAYS raise the valve from its seat with thelifting level periodically while the boiler is underpressure. Test by raising to popping pressureat least once per year.NEVER increase the setting of a safety valvewithout authority. Serious accidents haveoccurred from failure to observe this rule.ALWAYS consult an authorized boiler inspectorand accept his or her recommendations beforeincreasing the safety-valve pressure setting.NEVER change adjustments of a safety valvemore than 10 percent. Proper operationdepends on the proper spring.ALWAYS have the valve fitted with a new springand re-stamped by the manufacture for changesover 10 percent.NEVER tighten a nut, bolt, or pipe thread understeam or air pressure. Many have died doingthis.ALWAYS play safe on this rule. The one that isgoing to break does not have a special warningsign.NEVER strike any object under steam or airALWAYS play safe on this rule. You cannot tell
 
pressure. This is another sure path to theundertaker.which straw might break the camel’s back.
 
NEVER allow unauthorized persons to tamperwith any steam-plant equipment. If they do notinjure themselves, they may cause injury to you.ALWAYS keep out loiterers and place plantoperation in the hands of qualified persons. Aboiler room is not a place for a club meeting.NEVER leave an open blow down valveunattended when a boiler is under pressure orhas a fire in it. Play safe; memory can fail.ALWAYS check the water level before blowingdown and have a second person watch thewater gauge level while you blow down theboiler. Close the blow down valve, and thenrecheck the water level. You will avoid dry-firingthe boiler this way.NEVER allow anyone to enter a drum of a boilerwithout following OSHA rules for entering aconfined space.ALWAYS make sure the boiler is cool to enter,has enough oxygen per OSHA rules, has a signby the entrance stating “Worker Inside”, has anemergency person at the entrance, and that allvalves going to and from the boiler are lockedand closed.NEVER allow major repairs to a boiler withoutauthorization. If you do not break a law, youmay break your neck.ALWAYS consult an authorized boiler inspectorbefore proceeding with boiler repairs.NEVER try to light a second burner from theflames of the first on-line burner. You might beinviting a serious puff back.ALWAYS follow the starting sequence of themanufacturer on multi-burner boilers, includingignition and main flame proving by installedburner controls, and you will avoid a furnaceexplosion.NEVER attempt to light a burner without ventingthe furnace until clear. Burns are painful.ALWAYS allow draft to clear furnace of gas anddust for prescribed purge period. Change draftconditions slowly.NEVER fail to report unusual behavior of aboiler or other equipment. It may be a warningof danger.ALWAYS consult someone in authority. Twoheads are better than one.
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