Instructions for labor protection when servicing boilers with electric heating

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Instructions for labor protection when servicing boilers with electric heating

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. This instruction contains requirements for ensuring the safe operation of electrically heated boilers and is compiled on the basis of the manufacturer’s instructions for installation and operation

1.2. Persons at least 18 years of age who have undergone special training, a medical commission, have a certificate with a photo for the right to service electrically heated boilers and have Group III electrical safety are allowed to service boilers.

1.3. Re-inspection of the boiler room personnel is carried out at least once every 12 months.

1.4. When entering duty, personnel are required to familiarize themselves with the entries in the log, check the serviceability of the equipment and all boilers installed in the boiler room, the serviceability of the lighting and telephone, as well as the presence and serviceability of grounding.

Acceptance and delivery of duty must be documented by the operator with an entry in the shift log indicating the results of checking the boiler and related equipment (pressure gauges, safety valves, power supply devices, automation and electrical equipment).

1.5. It is not allowed to accept and hand over the shift during the liquidation of the accident.

1.6. Unauthorized persons access to the boiler room is allowed by the head of the enterprise.

1.7. The boiler room, boilers and all equipment, passages must be kept in good condition and proper cleanliness.

1.8. Doors for exiting the boiler room should open easily to the outside.

1.9. Boiler elements may only be repaired if there is no pressure at all. Before opening hatches and hatches located within the water space, the water from the boiler elements must be drained.

1.10. It is allowed to carry out work inside the furnaces and flues of the boiler only at a temperature not exceeding 50°C with the written permission of the person responsible for the good condition and safe operation of the boilers.

1.11. Before starting repair work, the furnace and gas ducts must be well ventilated, lit and reliably protected from possible penetration of gases and dust from gas ducts of operating boilers.

1.12. Before closing hatches and manholes, it is necessary to check if there are any foreign objects inside the boiler.

2. Preparation of the boiler for start-up

2.1. Before starting the boiler, check:

serviceability of electrical equipment, locking and control devices;
serviceability of instrumentation, fittings, nutritional devices;
fill the boiler with water up to the ignition level mark.

3. Boiler start

3.1 The boiler is started in manual mode.

The 1PP switch is set to the “MANUAL” position, and the power supply circuit of the EV is opened along the automatic control line.

Rectifier D1 is shunted by the contacts of switch 1PP and current relay 14PP is disconnected from the boiler control system. The automatic pressure control system is also disabled

3.2. The boiler power or pressure is controlled manually using the 3PP switch, which closes or opens the power supply circuit of the electronic device and, accordingly, opens or closes the computer. In this case, control is carried out visually using the readings of an ammeter, pressure gauge and level indicator.

4. Boiler operation

4.1. During operation, the operation of the boiler is carried out automatically. Heating and evaporation of water occurs due to the release of heat when passing through the boiler water between electrodes with different potentials. The total value of the current passing through the water depends on the depth of immersion of the electrodes and the resistivity of the water.

4.2. The automatic control system of the boiler provides the following functions: automatic maintenance of the specified power and, therefore, the steam output of the boiler at one of the following power levels 25%, 50%, 75%, 100% power, which corresponds to 60 A, 120 A, 180 A, 240 And, and also;

elimination of water hammer;
automatic maintenance of the specified pressure in the boiler;
work in manual mode;
short circuit protection;
protection against overfeeding the boiler with water;
automatic power off when opening the boiler casing doors.

4.3. The operation of the circuit for automatically maintaining the specified power is carried out using the 2PP switch, while the 1PP switch is set to the "automatic" position, and the 3PP switch to the "off" position.

4.4. The operation of the circuit for automatically maintaining the specified pressure in the boiler occurs in the following order. At a given steam flow rate and an increase in the level in the boiler, the pressure rises, when the pressure rises to the upper setting of the EKM, the 1RP relay is activated and the NO contacts close the power supply circuit of the EV, while the EMW opens, at the same time the 1RP relay becomes self-locking. The water level starts to drop, the current, steam production and, the pressure in the boiler decreases, the EKM min contacts close, the 2RP relay is activated and the NC contacts break the self-locking circuit of the 1RP relay, which is de-energized and the NO contacts break the power circuit. In this case, the EMW closes and the cycle repeats.

4.5. The protection of the boiler from overwatering is carried out in the following order.

At a certain height, a limit level sensor of the VU electrode type is installed in the column of level sensors. When the water reaches the sensor VU, the power circuit of the 4RP relay is closed, which closes the HP power circuit with NO contacts, the 1A automatic machine is triggered, and the boiler is de-energized.

4.6. The low water protection works in the same way.

4.7. While on duty, boiler personnel must monitor the serviceability of the boiler(s) and all boiler room equipment and strictly adhere to the established operating mode of the boiler. Malfunctions detected during equipment operation must be recorded in a shift log. Personnel must take corrective action. If it is impossible to eliminate malfunctions on your own, then you must inform the boiler house manager or the person responsible for the good condition and safe operation of the boilers.

4.8. Particular attention must be paid to:

to maintain a normal water level in the boiler and uniform supply of water to it. At the same time, the water level must not be allowed to fall below the set value, while replenishment is strictly prohibited;
to maintain normal steam pressure according to the pressure gauge (6kg / cm2);
on the amount of current flowing

4.9. Checking the health of the pressure gauge using three-way valves, checking the health of the safety valve by forced opening, purging the low points should be carried out by the operator every shift with an entry in the logbook.

4.10. All devices and devices for automatic control and safety of the boiler must be maintained in good condition and regularly checked, within the prescribed time limits, by the administration.

5. Boiler stop

5.1. It is carried out only on the written order of the person responsible for the good condition and safe operation of the boilers.

5.2. Turn off the power supply to the boiler with the handle of the machine 1AB

5.3. Close the main steam valve and open the drain.

5.4. Ventilate the furnace and gas pipelines.

5.5. Close the valve at the water inlet and outlet of the boiler.

5.6. Make an entry in the shift log when the boiler stops.

6. Emergency stop of the boiler

6.1. If a failure of one of the safety valves is detected.

6.2. If the steam pressure has increased by 10%, exceeding the permitted pressure, and does not decrease despite the measures taken (increased supply of water to the boiler, load reduction).

6.3. When the water level drops below the permissible mark. Make-up is strictly prohibited, which can lead to an explosion of the boiler.

6.4. When the level rises above the set mark.

6.5. In case of failure of all water-indicating devices.

6.6. When they fail all feed pumps.

6.7. Upon detection of the main elements of the boiler breaks, cracks, bulges.

6.8. When the power supply is interrupted.

6.9. In the event of a fire that threatens the operating personnel and the boiler.

In case of emergency shutdown of the boiler, it is necessary:

Turn off the boiler with the handle of the machine 1AB.
Monitor the water level in the boiler, close the main steam valve.
Make an entry in the watch log about the reasons and time of the boiler shutdown, notify the head of the boiler room about the emergency shutdown of the boiler.

In the event of a fire in the boiler room, the personnel must call the fire brigade and take all measures to extinguish it without stopping monitoring the boilers.

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