Page 21 - Boiler Operator’s Handbook

6 Boiler Operator’s Handbook

hundred people. The most expensive accident was a Prevention of explosions in boilers has come a long
boiler explosion at the River Rouge steel plant in Febru- way since the Sultana went down. The modern safety
ary of 1999. Six men died and the losses were measured valve and the strict construction and maintenance re-
at more than $1 billion. Boiler accidents are rare com- quirements applied to it have reduced pressure vessel
th
pared to figures near the first of the 20 century when explosions to less than 1% of the incidents recorded in
thousands were killed and millions injured by boiler the U.S. each year, always less than two. On the other
explosions. Today, less than 20 people die each year as hand, furnace explosions seem to be on the increase and
a result of a boiler explosion. I don’t want you to be one that, in my experience, is due to lack of training and
of them. I’m sure you don’t want to be one either. Safety knowledge on the part of the installer which results in
rules and regulations were created after an accident inadequate training of the operator.
with the intent of preventing another. You must know what the rules are and make sure
A simple rule like “always hold the handrail when that everyone else abides by them. A new service techni-
ascending and descending the stair” was created to cian, sent to your plant by a contractor you trust, could
save you from injury. Don’t laugh at that one, one of my be poorly trained and unwittingly expose your plant
customers identified falls on stairs in the office building to danger. Even old hands can make a mistake and cre-
as the most common accident in the plant. Follow those ate a hazard. Part of the lesson is to seriously question
safety rules and you will go home to your family healthy anything new and different, especially when it violates
at the end of your shift. a rule.
There are many simple rules that the macho boiler What are the rules? There are lots of them and
operator chooses to ignore and, in doing so, risks life some will not apply to your boiler plant. Luckily there
and limb. You should make an effort to comply with all are some rules that are covered by qualified inspectors
of them. You aren’t a coward or chicken. You’re operat- so you don’t have to know them. There should be rules
ing wisely. for your facility that were generated as a result of an
Hold onto the handrail. Wear the face shield, boots, accident or analysis by a qualified inspector. Perhaps
gloves, and leather apron when handling chemicals. there’s a few that you wrote or should have written
Don’t smoke near fuel piping and fuel oil storage tanks. down. When the last time you did that there was a
Read the material safety data sheets, concentrating on boiler rattling BOOM in the furnace a rule was created
the part about treatment for exposure. Connect that that basically said don’t do that again! Your state and
grounding strap. Do a complete lock-out, tag-out before local jurisdiction (city or county) may also have rules
entering a confined space and follow all the other safety regarding boiler operation so you need to look for them
rules that have been handed down at your place of em- as well. Here’s a list of the published rules you should
ployment. Remember who’s on the top of the priority be aware of and, when they apply to your facility, you
list. should know them.
PPE stands for personal protective equipment and
was an acronym that was readily ignored long before I ASME Boiler and Pressure Vessel Codes (BPVC):
was operating plants and for quite a while afterward. Section I—Rules for construction of Power Boilers a
Because I wasn’t required to wear ear protection I have a Section IV—Rules for construction of Heating Boilers a
lot of trouble hearing lots of things today. Luckily I was Section VI—Recommended Rules for Care and Opera-
b
smart enough to wear safety glasses and gloves when tion of Heating Boilers
Section VII—Recommended Rules for Care and Opera-
appropriate most of the time, but not always.
tion of Power Boilers b
I’m sure you will want to be able to see and hear c
Section VIII—Pressure Vessels, Divisions 1 and 2 (rules
those grandchildren when they come along and you
for construction of pressure vessels including de-
won’t want them to have to observe that grandpa (or
aerators, blowoff separators, softeners, etc.)
grandma as applicable) has deformed hands, burns or Section IX—Welding and Brazing Qualifications (the
other injuries that can only be described as ugly. Wear section of the Code that defines the requirements for
that PPE, I wish the rules were enforced better when certified welders and welding.)
I was starting out because I would be able to see and B-31.1—Power Piping Code
hear better now and I wouldn’t have to explain to my CSD-1—Controls and Safety Devices for Automatically
grand nieces and nephews (let alone the grandchildren Fired Boilers (applies to boilers with fuel input in
I couldn’t have) why my hands and face look the way the range of 400 thousand and less than 12.5 million
they do. Btuh input)