Boiler & Pressure Vessels

Safety Operation

E-Learning Training
BSTC
What is a Pressure Vessel?

◼ A pressure vessel is a vessel in

which pressure is obtained
from an external source, or by
the application of heat from an
indirect or direct source.
◼ Vessels may gases, vapors,
and liquids at various
pressures and temperatures.
Boiler & Pressure Vessels Components
 Fired & Unfired Pressure Vessels
◼ Fired pressure
vessel
– External heat
source
◼ Unfired pressure
vessel
– No external heat
source
 Electric Boilers
◼ A power boiler,
heating boiler,
high or low
temperature
water boiler in
which the source
of heat is
electricity.
High Temperature Water Boiler
◼ A water boiler
intended for
operations at
pressures in excess
of 160 psig or
temperatures in
excess of 250
degrees F.
 Hot Water Heating Boiler
◼ A boiler in which no
steam is generated, from
which hot water is
circulated for heating
purposes and then
returned to the boiler, and
which operates at a
pressure not exceeding
160 psig or a temperature
of 250 degrees F at the
boiler outlet.
 Process Steam Generator
◼ A vessel or system of
vessels comprised of
one or more drums
and one or more heat
exchange surfaces as
used in waste heat or
heat recovery type
steam boilers.
 Unfired Steam Boiler
◼ A vessel or system
of vessels intended
for operation at a
pressure in excess
of 15 psig for the
purpose of
producing and
controlling an
output of thermal
energy.
 Water Heater Supply Boiler
◼ A closed vessel in which
water is heated by
combustion of fuels,
electricity or any other
source and withdrawn for
use external to the system at
pressure not exceeding 160
psig and should include all
controls and devices
necessary to prevent water
temperatures from
exceeding 210 degrees F.
Safety Appliances
◼ Include, but not be limited to:
– Rupture disk device
– Safety relief valve
– Temperature limit control
– Pressure limit control
– Major gas train controls
– Low water cutoffs
– Flame supervisory unit (igniter)
– High and low gas pressure switches
– Trial for ignition limiting timer (15 seconds)
 Low Water Test
◼ Should be tested with the boiler operating, the
burner should shut off, if it does not it should be
investigated.
◼ Tests should be made daily on pressures >15 PSI
and weekly for others.
 Relief Valve
◼ An automatic pressure-
relieving device
actuated by a static
pressure upstream of
the valve which opens
further with the increase
in pressure over the
opening pressure.
◼ It is used primarily for
liquid service.
 Safety Relief Valve
◼ An automatic,
pressure-actuated
relieving device
suitable for use as
a safety or relief
valve, depending
on application.
Rupture Disk Device
◼ A non-reclosing pressure-relief
device actuated by inlet static
pressure and designed to
function by the bursting of a
pressure-containing disk.
Temperature / Pressure Relief Valve

◼ A valve set to relieve at a

designated temperature
and pressure.
Blowoff Equipment
◼ All materials used in the
fabrication of object
blowoff equipment should
comply with code.
◼ All blowoff equipment
should be equipped with
openings to facilitate
cleaning and inspection.
◼ Open valves on each low-
water fuel cutoff valve, low
water alarm, tests the
switches and clears out
debris and obstructions.
 External Inspection
◼ As complete an
examination as can
be reasonably made
of the external
surfaces and safety
devices while the
boiler or pressure
vessel is in operation.
Note: When it comes to inspections, most pressure vessels should be
examined once before being placed into service and again every 5 years after
every alteration or major repair
 Internal Inspection
◼ As complete an examination
as can be reasonably made
of the internal and external
surfaces of a boiler or
pressure vessel while it is
shut down and while manhole
plates, handhole plates or
other inspection opening
closures are removed as
required by the inspector.
Hydrostatic Test Applied to Existing Vessels

◼ To determine tightness, the hydrostatic test

pressure need be no greater than the set
pressure of the safety valve having the lowest
setting.
◼ For safety tests, the pressure should be equal
to 2 times the maximum allowable working
pressure, less corrosion factor, as applicable.
◼ All major repairs and alterations should require
a safety test.
Common Failures Of Pressure Vessels

◼ Error in design and

construction
◼ Improper operation
◼ Corrosion
◼ Failure to inspect
properly
◼ Lack of preventative
maintenance
Hazards Related To Pressure Vessel
• Cracked and damaged vessels can result in
leakage or rupture failures.
• Potential health and safety hazards of leaking
vessels include
a. Poisonings
b. Suffocations
c. fires, and explosion hazards.
• Rupture failures can be much more catastrophic
and can cause considerable damage to life and
property
 The Safety Precautions
Timely Maintenance:
• Regular maintenance with a proper
maintenance program of the entire pressure
system, which checks the age of the vessel.
• Check for any signs of wear or corrosion.
Proper Knowledge and Training:
• The person operating or handling pressure vessels
should have a proper skill & knowledge about the
equipment.
• Necessary training must be given to those who are
responsible for repairing, maintaining, installing, or
checking the pressure of the equipment.
 The Safety Precautions
Understanding Operating Conditions:
• A proper understanding about the gases or
liquids contained in pressure vessels, along
with its nature – toxic or flammable.
• Know the operating conditions, which
include temperatures and pressures.
• Having the correct information about
system’s operating limits it extremely
important.
 The Safety Precautions

Installing Protective Devices:

• Ensure that suitable protective devices are
installed, and adjusted to the correct settings.
• Keep these protective devices in good working
condition.
• The protective devices should only be operated
or altered by an authorized person.
 Controlling Boiler Fires
◼ Fully enclosed boiler room
◼ Fire rated doors and walls
◼ No combustible materials
 Fire Protection
◼ Provide clearance around boilers
– Loss control strategies
◼ Boiler explosions and fires
– Testing program
– Safety relief devices
◼ Repair program
– Preventative maintenance program
◼ Keep a boiler log
 Air and Ventilation
◼ A permanent source of outside air should be
provided for each room to permit satisfactory
combustion of fuel and ventilation if
necessary under normal operations.
◼ The minimum ventilation for coal, gas, or oil
burners in rooms containing objects is based
on the Btu’s per hour, required air, and
louvered area.