TOOL BOX TALKS Version: 00

Boiler System Operation And Maintenance Safety

May-2018

Boiler :
For a Standard Steam Operation in an industrial situation, Steam Raising Boiler, Liquid Fuel Feeding System, Fuel
feed system, DM water Plant, Steam Header and Consumption Points.
Safety Components of a standard Steam boiler are- Safety valve and Drain valve, Steam pressure-gauge
Low- water cutoff. Bottom blow-off and

Water level indicator (Water gauge glass):

A water gauge glass enables to observe and verify the actual level of water in a steam boiler. If not properly
cleaned and maintained, a gauge glass can appear to show a sufficient level of water when a boiler actually is
operating in a low-water condition.
Pressure gauge:

All boilers must be fitted with at least one pressure indicator.

Safety Valve:

The safety valve is the most important valve on the boiler. Safety valves prevent dangerous over pressurization of
the boiler. Safety valves are installed in case there is failure of pressure controls or other devices designed to
control the firing rate. All safety valves should be kept free of debris by testing the safety valve regularly.

Pressure Reducing Station:

The common method for reducing pressure at the point where steam is to be used is to use a pressure reducing
station. Other components included in the pressure reducing valve station are-The primary isolating valve - To shut
the system down for maintenance. The primary pressure gauge - To monitor the integrity of supply. The strainer -
To keep the system clean. The secondary pressure gauge - To set and monitor the downstream pressure.The
secondary isolating valve - To assist in setting the downstream pressure on no-load conditions.

Safety Tips for Boilers Operation:

 PPE to use such as helmet, Shoes, Safety belt etc to be used while carrying out stack monitoring.
 Ensure that the access ladder of the stack is in good condition
 Efficiency will be increased by ensuring the boiler is getting enough oxygen and that the burners are set-up
correctly.
 Safety valves. Ensure that a safety valve is installed with full-sized discharge piping properly supported and
directed to a point of safe discharge. Safety valve set pressure must be equal to or less than boiler
maximum allowable working pressure. Safety valve relieving capacity must be equal to or greater than
boiler output.

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 TOOL BOX TALKS Version: 00
Boiler System Operation And Maintenance Safety
May-2018

 Verify operation of boiler water feed system periodically. Prove low water cut off operation periodically.
Use proper water column blow down procedures. Do not tamper with low water controls. Replace
defective low water controls.
 Verify proper operation of bypassed controls periodically. Correct electrical wiring defects immediately. Do
not tamper with controls.

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