Safety In Engineering Industry >Chapter 3> Topic-Plant Layout Design & Housekeeping> Boiler Operations- Hazards in boiler operations & Safety measures for its operations

 Hazards in Boiler Operations & Safety measures for its operations

Hazards in Boiler operations

1) Accident hazards- 

• Falls from ladders, stairs and elevated platforms
• Slips and falls on the level, particularly on floors made slippery by water, fuel, oils, etc.
• Struck by falling objects
• Mechanical accidents when operating pulverizer and stoker in coal-fired boilers
• Burns from hot surfaces, hot water and escaping steam
• Electrocution or electric shocks
• Poisoning by carbon monoxide or by other combustion products in the air, particularly in the case of faulty ventilation or inadequate air supply to burners (acute carbon monoxide poisoning may cause headache, dizziness, nausea, unconsciousness, coma and death)
• Asphyxia due to breathing of oxygen-depleted air 
• Splashes of hydrazine and its derivatives on the skin may cause penetrating burns and severe dermatitis
• Splashes into the eyes of chemicals used in the regeneration of ion exchange columns, in derusting and descaling; particularly, splashes of hydrazine and its derivatives may cause permanent corneal lesions
• Punctures, cuts and amputations
• Fires and explosions (particularly from fuel leaks) and from rags soaked with fuel; fires of soot; explosions of gas-air mixtures within the boiler
• Bursting of boilers (because of overheating and overpressure, failure of structural components due to metal fatigue, etc.) with possible fires, and injury by the explosion wave, by flying fragments, flames, steam, excessive noise, etc. 

2) Physical hazards- 

• Excessive continuous noise levels - as high as 94 dBA
• Heat stress caused by prolonged work at high temperatures and relative humidity
• Potential exposure to radon 

3) Chemical hazards- 

• Irritation of eyes, respiratory tract and skin as a result of exposure to hydrazine and its derivatives, used as additives to boiler water; severe exposure may cause temporary blindness
• Irritation of the upper respiratory tract and coughing, as a result of inhalation of sulfur dioxide, particularly if burning high-sulfur fuels
• Pneumoconiosis from exposure to vanadium-containing dust, and to asbestos from the insulation, particularly during maintenance and repair work, and from exposure to respirable fly ash
• Dermatoses from exposure to fuels and to corrosion inhibitors (various organic or metalorganic compounds) and other water additives
• Asbestos may cause cancer; smoking strongly increases the risk
  

4) Biological hazards- 

• Development of fungi and growth of bacteria in the boiler room, due to the elevated temperature and humidity
• Presence of rodents and insects may result in bites and infectious diseases 

5) Ergonomic psychosocial and organizational factors-

• General tiredness as a result of physical work in a noisy, warm and humid environment;
• Cumulative trauma disorders as a result of continuous repetitive movements or over strenuous efforts
• Back pains and other musculoskeletal problems (including lesions of intervertebral discs) resulting from overexertion and wrong postures, during lifting and moving of sacks and heavy loads
• Psychological stress due to dissatisfaction at work, as a result of boredom, monotony, low salary, problematic personal relations with peers and/or superiors, etc. 

Safety Measures for Boiler Operation

1. Wear safety shoes with non-skid soles
2. Periodically check and adjust burners operation to prevent carbon monoxide generation
3. Install effective exhaust ventilation to prevent air contamination; add local exhaust ventilation if necessary
4. Wear long-sleeve shirts and protect hands with chemical-resistant gloves; if impractical, use a barrier cream
5. Wear appropriate eye protection; consult a safety supervisor or a supplier
6. Arrange periodic inspection of boilers, to detect failure of components, metal cracking, etc.
7. Wear hearing protection appropriate for the noise levels and type of noise - consult the supplier or an expert
8. Replace hydrazine with less-hazardous substitutes
9. Wear respiratory protection during maintenance or other work in which dust may be released into the atmosphere
10. Learn and use safe lifting and moving techniques for heavy or awkward loads; use mechanical aids to assist in lifting
11. Periodic check of heaters and controls.
12. Periodic checks of oil temperature and heaters
13. Ensure insulation of steam lines. Periodic check of trap operation 
14. Insulate all steam lines. Check proper trap operation periodically. Follow manufacturer’s instructions.
15. For worn automizer ,Regular service of tips. Gaskets should be replaced when cleaning or replacing tips.
16. For steam leaks ,All joints and pipes should be secured. 
17. Warnings to all workers about potential hazard. Allow sufficient cooling time before walking on fly ash. Hot fly ash should be removed with caution using equipment. Water should be sprayed on hot fly ash. 
18. Promptly replace or repair safety valve. Remove obstructions. Periodic test of safety valves. 
19. The gauge should be calibrated regularly. Defective gauges should be preplaced promptly. Periodic inspection of gauge connection and piping to boiler for blockage or closed cock.
20. Only trained and authorized workers should have access. Operators should be properly trained.
21. Ensure adequate air to boiler room. Combustion air fans should be clean and running properly. Periodic inspection of air inlets and outlets, combustion controls, boiler gas passages, hot fuel gas passage, dampers and hot flue gas temperature. 
22. Ensure all electrical wiring is secure and insulated
23. Ensure good housekeeping of the boiler room. Do not allow dumping of waste or unnecessary articles in the boiler room.
24. Keep floor drains clean, clear and unclogged.
25. Do not leave the boiler operation to a person who is not trained or qualified.
26. The operator should ideally have a formal qualification and training to run a boiler of given capacity.
27. Clear direction should be provided for start-up, running and shutdown procedures, blow down, high and low water conditions, and emergency procedures.
28. If a boiler plant is started remotely and/or automatically without warning, workers must be alert to avoid that equipment which can be started remotely.
29. The water for the boiler should be treated for hardness before using. Each boiler should have a temperature gauge.                                                                           

Reference: 

• Boiler Safety Compliance Book
• International Hazard Datasheet 
• Google.com