Boiler Safety Yes PDF

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

HAZARDS
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (16)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
9. BOILER SAFETY AND OPERATIONAL HAZARDS ............................................ 2
9.1 General.................................................................................................................. 2
9.2 Boiler Plant Safety Procedures .............................................................................. 2
9.3 Utility Hazards........................................................................................................ 3
9.3.1 Piping Systems ...................................................................................................... 3
9.3.2 Electrical Hazards.................................................................................................. 5
9.4 Process Equipment Hazards ................................................................................. 6
9.4.1 Hazards during Boiler Operation............................................................................ 6
9.4.2 Maintenance Hazards............................................................................................ 7
9.5 Chemical Hazards ............................................................................................... 13
9.5.1 Safety arrangements for feedwater chemicals..................................................... 14
9.6 Natural Catastrophe Hazards .............................................................................. 14
9.7 General Personnel Safety Practices .................................................................... 15
1 2005 - 08 - 30 T. Anttonen
0 2005 - 02 - 11 T. Anttonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
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safety_rev1.doc
This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other project or
purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005


HAZARDS
Osasto - Department Kohde – Subject Sivu - Page

9. BOILER SAFETY AND OPERATIONAL HAZARDS
9.1 General
Kvaerner Power Oy includes this section in the Operation Manual to

insure that the inherent hazards that exist around an operating boiler
are recognised. It is not intended that this section override existing
company or site safety rules.
In each plant, the hazards may vary slightly. However, there are
some safety recommendations that apply to all operations. These
hazards can be broken down into three areas:
1. Utilities hazards
2. Equipment hazards and
3. Chemical hazards.
These will be covered separately in the following sections.
One of the most important ways to avoid hazards is to have a

thorough understanding of the processes. Familiarity with each
system and good common sense will enable operators to run the
system, not only smoothly, but safely.
9.2 Boiler Plant Safety Procedures
As stated earlier, the safety rules and guidelines issued to the

employees are the primary precautions that are necessary for the
prevention of an accident. Employees should become very familiar
with these rules.
Operators should always utilise the safety equipment that is provided

or required by their management (hard hats, safety shoes, safety
glasses, hearing protection, gloves, breathing protection, protective
clothing or any other safety equipment required to perform the job
question).


HAZARDS

Operators should be aware of the location of fire extinguishers, eye

wash stations, safety showers, self-contained breathing apparatus,
First Aid Stations, and other safety equipment furnished for the plant.
Maintaining good housekeeping practices will also minimise safety

hazards such as tripping or slipping. When spills occur, the floor
should be washed as soon as possible. When construction or
maintenance is completed, the remaining debris should be cleaned
up and removed. It has been shown that housekeeping is a good
indication of safety attitude in general.
Investigation of an accident to determine its cause(s) may help to

prevent the same accident from reoccurring and will aid in the
correction or elimination of the hazard.
9.3 Utility Hazards
9.3.1 Piping Systems
1. Hot Medium Burning Hazards
One of the main hazards connected with the operation of boilers is

the possibility of being burned with the high pressure steam, hot
condensate, hot ash or hot fuel oil. Leaks in these piping systems
should be repaired as soon as possible. Temporary protection
should be put around the area until permanent repairs can be made.
All piping should be labelled to identify both the direction of the flow
and type of system. All hot piping should be properly insulated.
When working in the department remember that during operation

most of the substances like oil, ash, steam and condensates, are hot
(over 100°C) and under pressure, so be very careful when
opening equipment and piping.


HAZARDS

NOTE ! When servicing at points where the personnel have a

risk of getting steam, condensate or oil shower on them
when opening, say, the cover of a non-return valve, the
boiler operator or an expert named by him must check
that the piping is unpressurized / safe before the
work. This is absolutely necessary for safety.
Hot surfaces in areas frequented by personnel should be covered

with insulation for protection. When hot surfaces must be left
exposed, such as valve stems and sight glasses, operators should
be warned of the potential hazard.
Steam valve packing, steam traps, and pipe fittings that are leaking
should be repaired as soon as possible. Steam systems should be
isolated, bleed off, and locked out prior to performing maintenance.
At times, steam is used for cleaning out piping. Operators should

make sure that if hoses are used, they are designed for steam
service. Make sure the connections are tight and do not leak.
High pressure water is used in some pumps, coolers, and

condensers. As with steam, high pressure water can be hazard if a
small leak is undetected and left unrepaired. Extreme caution
should be exercised when using any wash-up water around a boiler
plant. Avoid accidentally admitting water into the furnace.
The temperature of preheated combustion air can be as high as

200°C and the temperature of flue gas in the furnace as high as
900°C. Therefore access doors in the furnace walls and air and
flue gas ducts must not be opened while the boiler is in
operation. The access doors shall always be closed carefully before
the boiler is started. It shall be noted that during operation there
is always small overpressure inside the CFB boiler furnace.
The seals of the access doors and all bellows compensators (fabric
bellows in particular) shall be inspected annually and replaced when
necessary. When moving around bellows compensators there is
always a risk of leak in them and so wearing of necessary protective
clothing is recommended.


HAZARDS

First Aid for Burns:
The potential for burns exist wherever hot medium is used or

surfaces are without isolation. The recommended first aid for burns
is to first apply cold water directly to the burn; then cover the area
with cool, moist application of gauze or bandage material to
minimise blistering.
If the burns are critical (second or third degree), transport the injured
person to the medical facility promptly.
2. Hazards by High Pressure Air
Be careful when mill air or instrument air is used. High pressure air
can be very dangerous to personnel especially in the area of the
face (eyes, ears).
Make sure all pressure air fittings make good connection and cannot
blow loose.
9.3.2 Electrical Hazards
As with steam, electrical equipment should never be worked on

unless it is de-energised and locked out. It is important to test-start
the equipment after locking out, to insure that the correct breaker
has been opened. This will remove the potential for electrical shock
or accidental start-up.
Electrical hazards fall into three categories; shock, burn and

ignition:
• The severity of electrical shock is dependent on several items,

nature of the electrical impulse, path the shock takes through the
body, etc.
• Burns are those caused by contact with electrical current.
• Ignition is where a chemical or gas burns or explodes when it
comes in contact with an electrical spark.


HAZARDS

Except for very low voltage exposure (below 24V) and very low body
current (below 0,2mA), it is difficult to state safe limits for electrical
exposure. Even low energy exposures can be hazardous for people
with heart problems.
NOTE! Even though electrical equipment installed around the

boilers is designed to be water tight, water being used
around electrical equipment always presents a
hazard, and therefore should be used with care.
9.4 Process Equipment Hazards
The process equipment in its normal use can present a hazard if not
operated or repaired in a safe manner.
All equipment should be operated according to the manufacturer's

recommended procedures. Operating personnel or operators should
be well trained in the recommended procedures. All maintenance on
equipment should only be performed according to the
manufacturer's instructions. Only recommended spare parts should
be used.
9.4.1 Hazards during Boiler Operation
The start-ups and stops of the boiler and its auxiliary equipment are
furnished with interlocks to guarantee safety. In certain cases the
interlocks can be bypassed from the control system or locally. The
control system gets the message of the interlock bypass. An
absolute requirement is that the interlock bypasses must also be
recorded in the diary of the control room or on a special control list.
Alarms which are visible in the header range of the display and are
also written out in the printer, alarm about exceeding the permissible
limit value in the operating situation in question. In this case the
operators must take appropriate measures to return to the normal
situation.


HAZARDS

NOTE! The high level transmitter interlock of the drum level is

+250 mm and the low level transmitter interlock -250 mm. Both
interlocks function according to 2/3 principle stopping firing. The high
level safety device interlock of the drum level is +300 mm and the
low level safety device interlock -300 mm. For testing the
functionality of the safety device the drum level interlocks can be
bypassed by a separate key switch, transmitter interlocks are active
all the time. ( During bypass the drum level must be monitored
manually on line ). Key is normally in possession of chief operation
supervisor.
Instrumentation and controls should always be kept in good working

order to help assure the safe operation of equipment. Never pull
instruments or controls out of operation while equipment is in the
control of an instrument.
9.4.2 Maintenance Hazards
Kvaerner Power Oy designs all vessels, fittings and pipe to a

pressure higher than the operating pressure. In the repair or
replacement of a piece of equipment, pipe or accessories furnished
by Kvaerner Power Oy, Kvaerner Power Oy’s specifications should
be followed to insure that correct pressure rating is used.
Further, if an high pressure vessel requires repair of any kind, an

authorised inspector should approve that repair, to maintain the
validity of the design code.
Operating manuals with operating instructions are furnished for

supplied equipment. All designs are checked for proper capacity,
and for proper thickness of materials to assure safe operation. All
equipment is pressure tested at a higher than design operating
pressure (normally 1,5 times the design pressure).
NOTE! To avoid all kinds of hazards during repair work at the

power plant, Kvaerner Power Oy recommends the
use of written permissions. In that case the person
giving permission shall examine the place of work
thoroughly in terms of safety before granting
permission.


HAZARDS

1. Pumps and Pipings
Maintenance on pumps, pipe, etc. should be performed only after

valves are closed and locked out, or blanks are installed to
completely isolate the equipment.
Do not forget to make sure the place of work is pressure-free by

opening the purge or drain valve, unscrewing the pressure gauge or
the impulse tube before the work is started.
2. Vessels, Tanks and Silos
When it becomes necessary for an operator or a maintenance

person to enter a closed vessel, tank or silo, it should only be done
after the equipment has been properly locked out, cleaned out,
cooled down, and checked for the absence of CO and for sufficient
oxygen. Many gases are heavier than air and can collect in the
lower portion of the tank or vessel.
• Maintain always sufficient ventilation when working in vessels,

tanks or in silos.
3. Inspection of Fluidized Bed Sand
In connection with inspections of the fluidized bed or removal of

sintered sand note the following:
• Make sure the furnace has no carbon monoxide (gas analyzer).

Sand below the sintered surface may be burning hot (risk of
carbon monoxide).
• Do not go into boiler furnace and work there alone.
• When the furnace walls are cooling, lumps may fall (be sure to
wear a hard hat).
• Maintain always sufficient ventilation before going inside and
when working in boiler furnace.


HAZARDS

4. Service and Maintenance Work of Conveyors and Solid Fuel

Silos
The conveyors are delivered in accordance with safety regulations,

equipped with necessary covers, manholes and service hatches.
• Its always recommended to handle fuel conveyors and silos by

extinction steam and then purge with pressure air before
inspections inside. Do not forget to always maintain sufficient
ventilation before going inside.
• The conveyors must always be stopped before repair, service
and cleaning.
• Radiographic level indicators and flow measurements have been
blocked off in service position before going inside in the
equipment.
• Extinction steam isolation valves are closed before going inside
in the equipment.
• The safety switch of the conveyor must always be turned
into 0-position before service or repair work! (recommended
to secure with personal lock)
• For welding and oxygen cutting works there must be a special
permission and the work must be done as required by the
permission.
• Make always sure that the conveyor cannot start during service.
• If the covers are removed for service, they must absolutely be
replaced after the work.
• After a fire or an explosion the conveyors and silos must be
handled by inert gas. (extinction steam)


HAZARDS

5. Inspection and Maintenance Work of the Air and Flue Gas

Ducts and Fans and in ESP
In connection with inspections of the closed air or flue gas ducts note
the following:
• Maintain always sufficient ventilation before going inside and

when working in the combustion air and flue gas ducts and fans
or in the ESP.
• The safety switch of the fans and electrical damper
actuators must always be turned into 0-position before
service or repair work! (recommended to secure with personal
lock) The high voltage of the I.D. fan and big air fans must be
disconnected properly from the switch plant before entry. ( the
mechanical switch must be opened)
• Pressurized air supply for pneumatic damper actuators
must always be closed before service or repair work!
(recommended to remove air supply hoses from actuator before
work)
• The electrostatic precipitator must be switched off as
informed in separate instructions from supplier before going
inside.
• When making inspections, there must be sufficient illumination
when going inside equipment. It is extremely important to reduce
the risk of fall when moving around in the large air and flue gas
ducts.
• In some operational situations, the control dampers and vane
controllers in the air and flue gas ducts can move very quickly.
Therefore, because of the risk of squeeze, you must not touch
the levers on them during boiler operation.


HAZARDS

6. Blockage Removal from Solid Fuel Feeding Chutes and from

Bottom Ash Removal Equipment
• Increase furnace under pressure before work with solid fuel

feeding chutes.
• The operator shall wear face shields, protective jackets and
gloves while cleaning fuel feeding chutes or bottom ash removal
equipment.
• Below the fuel rotary feeders there are gate dampers, which
prevent the access of hot flue gases from the furnace to the
conveyors. Closing the damper is recommended before the doors
of the rotary feeder are opened or any other maintenance work is
done in the fuel conveyors.
• The temperature of the bottom ash in the boiler is usually higher
than 800°C and in the vicinity of conveyors there is always a risk
of burn when the equipment is touched. Hot sand runs out like a
fluid even through a small hole. The hand-operated gate
dampers shall always be closed before the inspection doors
are opened in a situation of plugging, for instance.
7. Service and Maintenance Work of Sootblowers
The sootblowers are delivered in accordance with safety regulations,

equipped with necessary covers.
• The sootblowers must always be stopped before repair, service

and cleaning.
• The isolation valve in sootblowing steam line must be closed
and the safety switch of the sootblowers must always be
turned into 0-position before service or repair work!
(recommended to secure with personal lock)
• If the covers are removed for service, they must absolutely be
replaced after the work.


HAZARDS

8. Inspection and Maintenance Work of Fly Ash Handling

Equipment
Because of disturbances in burning process it is possible that the fly

ash in conveyors and in the silo includes a lot of unburned carbon
and personnel must note the following:
• When opening doors in the conveyors or in the silo use always

protective clothing. (fly ash can be hot and begin to burn when
coming into contact with air)
• Before starting to open inspection doors in the ash hoppers and
flue gas ducting make sure that you protect yourself against ash,
which might burst out.
9. Inspection and Maintenance Work on Oil Burners, Oil

Pipelines and other Oil Equipment
In connection with inspections or maintenance of the oil system

equipment, note the following:
• When opening oil system instruments and fittings always make

the system unpressurised, close and lock isolation valves.
Empty and clean the pipeline with steam before cutting and
welding work.
• Oil can begin to burn when coming into contact with sparks or
flame.


HAZARDS

10. General safety of the maintenance personnel
Before the work is started, the maintenance personnel shall always

be given sufficient safety training and clear instructions for
dangerous situations which might arise. It is recommended that the
following regular routines should be observed:
• Always explain to the maintenance personnel how to behave

when emergency lamps blink or a signal is heard at the plant.
• At the end of the working day make sure each member of the
maintenance crew has left their places of work.
• When closing the access doors, do not forget to first make sure
that there are no persons left in silos, tanks, ducts or equipment.
The person who closes the door is always responsible for
adequate checking.
9.5 Chemical Hazards
In the normal operation of the boiler, many chemicals are present;

therefore, the potential of fire, exposure to a toxic condition, or burn
can exist. Operators should be made very aware of the following:
• Chemical substances present.

• Toxicity of the material.
• Antidote for exposure to the chemicals.
• Protective clothing needed.
• Potential fire hazard of the chemicals.
• Any other information that will help operators being aware of the
potential hazard of the chemical.
Most process chemicals are very caustic and will cause serious
burns if they come into contact with the skin or eyes. Operators
should be careful when opening valves and working on lines and
pumps. Safety glasses with side shields are recommended when
working around chemicals. Operators should familiarise themselves
with the location and operation of safety showers and eye wash
stations. Periodically, these stations should be inspected for proper
operation.


HAZARDS

A combustible material will spontaneously start to burn when its

temperature is raised to its ignition point in the presence of air. The
ignition point of all chemicals used in the process should be known
and posted for operators. In some cases, the mixture of vapour and
air can burn violently in the form of an explosion.
Since different persons react to chemicals in different ways, it is

difficult to establish an absolute evaluation of the toxicity. However,
most toxic materials do not have particularly adverse effects when
present in small amounts. Consequently, the concept of the
"threshold limit value" (TLV) has been developed and is defined as
that concentration of toxic material below which it is believed nearly
all individuals may be repeatedly exposed over a long duration
without adverse effects. The TLV's should be known for all
chemicals used.
9.5.1 Safety arrangements for feedwater chemicals
NOTE! See the chemical supplier’s safety instructions
9.6 Natural Catastrophe Hazards
In case a natural catastrophe occurs in an intensity that is frightening

by nature, the operation of the plant should be discontinued. Before
restart, the plant should be inspected by the people responsible for
the operations. As a result of careful inspection, they should decide
case by case if there is an immediate safety risk that delays the
normal operation. In case the safety risk is evident, all the damages
should be repaired.
After each seismic event causing an observable damage or a peak

ground acceleration of more than 0.10g at the site, the safety of the
installation shall be inspected. The steel frame and the supporting
structures of the equipment and their connections shall also be
inspected. A structural engineer familiar with steel and connection
performance at earthquakes should carry out the inspection.


HAZARDS

9.7 General Personnel Safety Practices
The most important design criterion has been as safe as possible

boiler plant for the operators. The operators are, however, the most
decisive factor as to their own safety.
The operator can affect his safety best by following instructions

for the plant and the safety on each individual job site carefully:
1. Wear safety glasses, ear protection and hard hats in all

operating areas except the control room, test labs, office and
training room areas, and electric rack rooms and motor control
centres.
2. All employees should wear appropriate clothing; long sleeve

shirts or protective jackets should be worn when punching
furnace sight glasses and oil lances.
3. The operator must wear face shields while cleaning sight

glasses, ash hoppers, oil burner throats; while changing oil
lances; while unplugging lines or furnace taps; or taking solid fuel
samples.
4. Do not use compressed air for cleaning clothing on yourself or

anyone else.
5. Open steam valves slowly (assuring that condensate is properly

bled off the pipe). Do not "jam" valves open.
6. Carry a flashlight when entering an unlit or poorly lighted area.
7. Keep your personal safety equipment in good condition.
8. Do not use sharp tools for unplugging furnace openings and

grate bottom.
9. Keep water away from hot ash. Newer allow water to enter
boiler furnace.


HAZARDS

10. Keep water and pressure air hoses rolled up when not in use.
11. Keep tools picked up and stored.
12. Deposit trash in proper receptacles.
13. Keep doorways and stairs free of debris.
14. Do not climb without a safety harness on piping, railing or any

steel structure over 1,5 meter above a floor.
15. Do not over-extend your reach while working from a ladder.
16. Do not disconnect alarms; correct the fault.
17. Report safety hazards and equipment malfunctions immediately.
18. Keep your work area clean and tidy, it is your responsibility.
19. Wear gloves when working around the boiler.

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Asiakirjan nimi - Name of Document Tunniste - Identification Rev.

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde - Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 1 (16)

9. BOILER SAFETY AND OPERATIONAL HAZARDS ............................................ 2

© Kvaerner Power Oy, Tampere, Finland 2005

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 2 (16)

9. BOILER SAFETY AND OPERATIONAL HAZARDS

Kvaerner Power Oy includes this section in the Operation Manual to

These will be covered separately in the following sections.

One of the most important ways to avoid hazards is to have a

9.2 Boiler Plant Safety Procedures

As stated earlier, the safety rules and guidelines issued to the

Operators should always utilise the safety equipment that is provided

© Kvaerner Power Oy, Tampere, Finland 2005

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 3 (16)

Operators should be aware of the location of fire extinguishers, eye

Maintaining good housekeeping practices will also minimise safety

Investigation of an accident to determine its cause(s) may help to

9.3 Utility Hazards

9.3.1 Piping Systems

1. Hot Medium Burning Hazards

One of the main hazards connected with the operation of boilers is

When working in the department remember that during operation

© Kvaerner Power Oy, Tampere, Finland 2005

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 4 (16)

NOTE ! When servicing at points where the personnel have a

Hot surfaces in areas frequented by personnel should be covered

At times, steam is used for cleaning out piping. Operators should

High pressure water is used in some pumps, coolers, and

The temperature of preheated combustion air can be as high as

© Kvaerner Power Oy, Tampere, Finland 2005

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 5 (16)

First Aid for Burns:

The potential for burns exist wherever hot medium is used or

2. Hazards by High Pressure Air

9.3.2 Electrical Hazards

As with steam, electrical equipment should never be worked on

Electrical hazards fall into three categories; shock, burn and

• The severity of electrical shock is dependent on several items,

© Kvaerner Power Oy, Tampere, Finland 2005

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 6 (16)

NOTE! Even though electrical equipment installed around the

9.4 Process Equipment Hazards

All equipment should be operated according to the manufacturer's

9.4.1 Hazards during Boiler Operation

© Kvaerner Power Oy, Tampere, Finland 2005

BOILER SAFETY AND OPERATIONAL CFBT-582-1 1

Osasto - Department Kohde – Subject Sivu - Page

Power Generation RAPP PB3 PROJECT 7 (16)

NOTE! The high level transmitter interlock of the drum level is

Instrumentation and controls should always be kept in good working

9.4.2 Maintenance Hazards