‫تقييم مخاطر الغاليات‬ BOILER RISK ASSESSMENT

TASK HAZARD The cause Risk EXISTING RISK ANALYSIS (WITH ADDITIONA RISK ANALYSIS( WITH
CONTROL EXISTING CONTROL) L CONTROL ADDITIONAL CONTROL)
SEVERIT LIKLIHOO LEVE SEVERIT LIKLIHOO LEVE
Y D L Y D L
OPERATING High fuel Improper -Oil -Periodic 5 2 10
BOILER temperature setting of gasification. check of
Oil firing thermostat. -Poor heaters
Steam control atomization. and controls.
valve stuck -Unstable - qualified
open in steam flame. technician
heater. - Fireside -
Electrical explosion.
supply -Fire.
contacts -Damage to
welded boiler and
closed in assets
electrical damage.
heater -Loss of life or
explosion. injury.
Low fuel Faulty heater Smoky fire. Periodic 5 2 10
temperature element. Low Poor checks of oil
setting of oil atomization. temperature
temperature Discharge of and heaters.
control. unburned oil
Steam supply in the furnace.
disrupted or Fireside
closed. explosion Fire.
Electric Damage to
power of boiler and
heater off. assetsdamage.
Explosion. Loss of life.
Wet steam Steam line Smoky fire. Ensure 5 2 10
during not insulated. Poor insulation of
atomizing Steam traps atomization. steam lines.
not working. Sparkles in Periodic
Steam wet flame. check of trap
from source. Unburned oil operation
Explosion. discharged in
 furnace.
Fireside
explosion.
Fire.
Damage to
boiler and
assets.
Loss of life.
Low steam Improper - Smoky fire. Insulate all 5 2 10
pressure setting of - Poor steam lines.
control atomization. Check proper
valve. Supply - Unburned oil trap
line valves discharged in operation
inoperative or furnace. periodically.
not open. - Fireside Follow
Low supply explosion. manufacturer’
pressure. - Fire. s
Explosion. - Damage to instructions.
boiler and
assets.
- Loss of life
and/ or
injury to
personnel.

Worn or Normal wear Incomplete Regular 5 2 10

damaged and tear. combustion. service of tips.
atomizer Abrasive Flare back. Gaskets
material in Fire. should be
oil. replaced when
Burner tip not cleaning
serviced. or replacing
Explosion. tips.

Gas firing Gas line leaks Improperly Explosion. Ensure 5 2 10

assembled Asphyxiation. adequate
joints. Fire. ventilation.
 Excessive Piping, valves
pressure. and fittings
Leaking should be
gasket. well
Damage to maintained.
piping, Test of
valves and leaks and
fittings safety devices
carrying before
fuel. operation
Gas Line Damage Explosion. Accepted 5 2 10
Repair Piping or Fire. Loss of methods of r
valves life purging and
or injury. recharging
Damage to gas lines
assets. should be
used
High Gas Defective gas Fuel rich Monitor for 5 2 10
pressure pressure mixture. regulator
regulation. Fireside operation.
explosion. Check
Fire. Loss of operation and
life setting of
or injury. pressure
Damage to switch
boiler periodically.
and assets. Repair or
replace
defective
regulators and
switches.
Steam Leaks Steam Leaks Severe burns. All joints and 3 2 6
Damaged or pipes
corroded should be
pipes secured.
and pressure
parts
HOT FLY Accumulation Serious burn Warnings to 3 2 6
ASH s of hot fly injury all workers
 ash and fly about
ash in boiler potential
flues and hazard.
plenums. Allow
Workers sufficient
stepping on cooling
hot time before
fly ash. Fly ash walking on
may retain fly ash. Hot fly
heat for ash
several should be
weeks. removed with
No visible caution using
difference equipment.
between hot Water should
and cold fly be sprayed
ash. Explosive on hot fly ash
effect of
water on hot
fly ash.
Steam Low water Defective low Overheated Periodic 5 2 10
explosion level water cutoff boiler verification of
or low water surfaces. boiler water
cutoff Ruptured feed system.
bypassed. boiler. Loss of Periodic check
Improper life of low water
water and/or injury cut-off
column blow to personnel. operation.
down Asset damage. Water
procedure. column blow
Tampering down
with procedures
low water should be
control. correct. Do
Defective not tamper
boiler water with
feed system. low water
Defective or controls.
inoperative Replace
gauge glass. defective low
 Operator water
error. controls.
Periodic
inspection of
equalizing
lines.
Operators
should be
trained
properly.
Defective Obstruction No release of Promptly 5 2 10
safety valves. between excess replace or
boiler pressure. repair safety
and valves. Excessive valve.
Damaged or pressure on Remove
corroded the obstructions.
valve. Level boiler. Boiler Periodic test
tied ruptured. Loss of safety
down. Valve of valves.
outlet life and injury.
obstructed. Damage to
assets.

Defective Broken gauge Gauge will not The gauge 5 2 10

steam or poor show the should be
pressure calibration of correct calibrated
gauges. gauge. The pressure even regularly.
line when Defective
from boiler to the boiler is gauges should
gauge under be preplaced
blocked. excessive promptly.
Gauge cock is pressure. The Periodic
closed. operator will inspection of
Conflict of not be aware gauge
multiple of true connection
gauges. operating and
conditions. piping to
boiler for
blockage or
 closed co
Scaling or Poor Ruptured Regular
corrosion in maintenance boiler due to maintenance
boiler’s and test overheating. and
internal methods. Loss of life or inspections.
surfaces Improper injury to Keep
chemical workers. maintain log.
cleaning. Assets Boiler water
Improper damage. treatment
water should be
treatment appropriate
and
contaminated
boiler water.
Poor feed
water
control.
Bypassed Defective Malfunctionin Periodic test 5 2 10
controls. electrical g or no and
wiring. functioning of verification of
Control and controls. controls.
electrical Boiler Controls and
wiring ruptured. wiring
tampered. Explosion should no be
in furnace. tampered
Loss of life.
Damage to
assets.
Tampering Lack of Improper Only trained 5 2 10
with controls proper operation of and
training to boiler may authorized
workers lead to boiler workers
rupture. should have
Explosion in access.
furnace. Loss Operators
of life. should be
Damage to properly
assets. trained
Poor Lack of Fatal risk for Implement a
 maintenance maintenance workers and well
policy assets. Low documented
an procedure. operating maintenance
Poor or no efficiency and policy and
training to poor procedures.
workers. operation. Keep
Leads to high maintenance
repair and log
replacement
cost.
Condensate Improperly Excessive tank Traps in vent 5 2 10
tank vented tank pressure line should
explosion. or may lead to be eliminated.
vent too explosion. Vent
small. Vent Loss should be of
may be of life. full size
trapped. Damage to
Trapped vent assets
has
frozen
condensate.
Explosion in Inadequate Low pressure Delay in Ensure 5 2 10
furunce pilot/igniter. of oil or gas. ignition or periodic
Not correctly may maintenance
positioned. not ignite the of pilot.
The main flame. Correct the
nozzle may be Fireside pilot position,
too small. explosion. conduct
Improper Fire. periodic pilot
setting of Boiler verification
light-off. damage. Loss test
Damper. of life
Plugged and severe
orifice. injury.
Damage
to assets.
Ignition Pilot or Fire. Fireside Ensure
delayed. igniter is not explosion. adequate
adequate. Can damage pilot.
 Fuel pressure the boiler. Light-off
may Loss of life and fuel/aeration.
be low or fuel severe Pilot turndown
rate may not injury. test.
be sufficient. Damage to Excessive
Excessive air assets. restart
rate. Low oil attempts
temperature. should be
Water in fuel. avoided.
Combustion Lack of Delayed Ensure 5 2 10
air not adequate air ignition. adequate air
sufficient. openings in Combustion to
the boiler may be boiler room.
room. inadequate. Combustion
Dirty Fireside air fans should
combustion explosion. be clean
air blower. Loss of life and and running
Combustion severe injury. properly.
air blower Damage to Periodic
running too assets. Fire. inspection of
slow or Boiler air
slipping. damage. inlets and
Setting of Enhanced outlets,
fuel/aeration emissions. combustion
not controls,
proper. boiler gas
Blockage in passages, hot
blower fuel gas
inlet or in passage,
outlet dampers
damper. and hot flue
Boiler gas gas
passage may temperature
be
plugged
Combustion Lack of Can lead to Only 5 2 10
safety knowledge or fireside authorized
control poor explosion. personnel
tampered operator Fire. Loss of should
training. life conduct
 and serious maintenance.
injury. Operators
Damage should be
to boiler and properly
assets trained in
maintenance
and operation
procedure.
Leaks in fuel Defective Fuel can flow Periodic 5 2 10
safety valve. Foreign to the boiler. inspection of
shutoff objects under Uncontrolled valves.
valves. valve seat. ignition of Defective
fuel. Fireside valves
explosion. should be
Loss of life and replaced
severe promptly.
injury. Fire. Regular leak
Damage to test and
boiler and verification of
assets. valves’
operation.
implosions Excessive Flame out Damage to Control 3 2 6
negative equipment. equipment
pressure Serious risk of should be
injury. properly
operated and
should not
be bypassed.
maintenanc Equipment Lock out/ tag Can lead to The 5 2 10
e undergoing out not severe injury equipment
maintenance. followed, or should be
Sudden equipment death of replaced in
starting of not in workers zero energy
remotely zero state
controlled mechanical and zero
equipment. state, or not mechanical
Release of in zero energy state.
fluid pressure. state. Comply with
Electrical lockout and
shock. tag out
procedures.
Workers
should be
trained for
alertness. Post
warning
signs.
Cleaning Can lead to Carefully 5 2 10
severe injury follow all
or maintenance
Neglecting death of procedure
safety workers cleaning.
procedures Provide
for appropriate
maintenance protective
cleaning clothing to
workers.
Regular
cleaning and
removal of
ash,
soot, slag etc
can prevent
excessive
accumulation.
Entering a Can be Con lead to Ensure 5 2 10
confined or extremely severe injury sufficient
enclosed hazardous or ventilation
space such as due to toxic death of for the fresh
furnace, or workers air. Conduct
ducts, drums, inflammable test for
shell, gas oxygen oxygen
passes, flues, deficient deficiency,
tanks, atmosphere toxic or
bunkers, and hot inflammable
hoppers, material. gases
tec. before
entering.
Ensure
 adequate
lights before
entering an
enclosed
space.
Follow all
applicable
safety
rules.
Airborne Ventilation or Can lead to Ventilation or 5 2 10
contaminants exhaust not sever injury or exhaust
such as gases, proper. death of system should
fumes, Leakage. workers be in good
vapors, dust working
and mist condition.
Provide
respiratory
mask
and protective
clothing
Moving Safety guards Can lead to Ensure safety 4 2 8
equipment or missing severe injury. guards are
parts and fan installed.
blades in Loose clothing
exposed and long hair
condition should be
avoided.
Congestion in Poor Risk of falls, All equipment 3 2 6
work area housekeeping slips and trips should
. leading to have clear and
injury. unobstructed
access.
Maintain good
housekeeping.
Accidental Closed door is Risk of bodily Ensure all 2 2 4
opening of not locked or injury access doors
the access bolted. are locked.
door.
Exposed/ Risk of severe Ensure all
ELETRICAL naked electrical electrical
electrical Damaged or shock causing wiring is
wiring no insulation. injury, burns secure and
Poor or even death insulated
maintenance.
Exposed Risk of severe Ensure 5 2 10
electrical electrical electrical
boxes shock causing boxes
Negligence injury, burns are covered
or even death
Switch box Risk of severe Safety catch 5 2 10
opens Safety catch electrical should be
without damaged shock causing repaired
turning off allowing injury, burns immediately
powers. opening or even death.
without
shutting off
power.