Q17. Flu-gas temperatures should be at how many degrees above steam production temperature during boiler operations?

Q18. When securing a boiler, at what pressure should you open the drum vent valves?

Q19. What is the purpose of a boiler operating log?

SAFETY

Learning Objective: Understand the relationship of safety in operating and maintaining boilers. Recognize the different types and use of lockout devices in boiler maintenance.

In servicing boilers, the need for SAFETY cannot be overemphasized. Much progress has been made over the years in the development of safety devices for boilers. There are still many ways, however, in which serious accidents can happen around boilers. A boiler operator or serviceman who is careless on the job threatens the safety of everyone. Accidents somehow have a way of happening at a moment we least expect. All the more reason, therefore, for constant alertness and close attention to detail. Do not take chances! BE SAFETY CONSCIOUS!

Some of the major safety precautions to be observed by Utilitiesmen engaged in boiler operation and servicing are presented below. As protection against toxic or explosive gases, boiler settings must be ventilated completely and tested for toxic or explosive gases before crews are permitted to enter.

The covers of manholes must be removed for ventilation before people enter the drum.

Before anyone enters a steam drum, mud drum, or other waterside enclosure, steam and feed lines connected to the headers under pressure should be isolated by a stop valve and a blank with an open telltale valve in between, or by two stop valves with a telltale valve opened in between.

A ventilating fan should be operating in the drum when someone is working in the boiler.

Workers should not be inside the waterside of the boiler when pressure is being applied to test a valve that has not been under pressure.

Workers should wear protective clothing when making boiler water tests.

Boiler settings must be examined daily for external air leaks. Cracks, blisters, or other dangerous conditions in joints, tubes, seams, or blowoff connections are to be reported to your senior chief petty officer immediately.

Boilers should also be examined regularly for deposits on their heating surfaces and for grease or other foreign matter in the water. Boilers showing any such faults should be cleared at the first opportunity and should not be used until cleared.

Performing certain adjustments and repairs while pressure is up is prohibited. A complete absence of pressure is to be ensured by opening the air cock or test and water gauge cocks connecting with the steam space before fittings or parts subject to pressure are removed or tightened, and before manhole or handhole plate fittings are loosened on a boiler that has been under pressure.

Combustion control, feed control, and burner, stoker, or similar adjustments are permitted with the boiler steaming, since many adjustments can be made only when pressure is up.

When cleaning operations are performed, workers should wear the proper personal protective equipment. The following requirements apply:

Hard hats and goggles must be worn.

When a worker is chopping slag inside a furnace, a respirator must be worn.

Safety-toed shoes or toe guards must be worn to prevent injuries from falling slag.

When someone is working inside the furnace, a large warning sign, such as Caution-Man Working Inside, should be placed near the furnace entrance.

The use of open-flame lights is prohibited in boilers. When cleaning where flammable vapors and gases may be present, workers are to use only explosionproof portable lamps equipped with heavily insulated three-wire conductors, with one conductor connecting the guard to ground.

Oil accumulated on furnace bottoms should be cleaned out immediately.

The fuel-oil suction and discharge strainers should be cleaned at least every 8 hours and more frequently if necessary.

Condensate pits in boiler rooms should have metal covers. If the pits must be opened for maintenance, adequate guards should be placed around them and warning signs posted.