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Instructions for labor protection when servicing gaseous fuel steam boilers

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 steam boilers and is compiled on the basis of the standard instruction of the Gosgortekhnadzor of the Russian Federation.

1.2. Boiler servicing is allowed for persons not younger than 18 years of age who have undergone special training, a medical commission, who have a certificate with a photograph for the right to service natural gas boilers.

1.3. The boiler operator must:

• undergo repeated training on labor safety at the workplace at least every three months;
• pass a knowledge test on the rules for the design and safe operation of steam and hot water boilers, steam and hot water pipelines, safety rules in the gas industry;
• undergo a medical examination in accordance with the order of the Ministry of Health of the Russian Federation No. 90 dated 14.03.96;
• perform only the work that is part of his duties.

1.4. The operator must know:

• rules for the design and safe operation of steam and hot water boilers;
• rules for the safe operation of gas equipment;
• the effect on a person of dangerous and harmful factors that arise during work;
• requirements for industrial sanitation, electrical safety, fire safety;
• rules of internal labor regulations;
• the requirements of this manual;
• appointment of personal protective equipment;
• be able to provide first aid in case of an accident.

1.5. During operation, the operator may be exposed to the following hazardous production factors:

• high pressure and temperature of heating surfaces;
• high voltage in the electrical network;
• increased levels of noise and vibration;
• increased air movement.

1.6. The operator must use the following personal protective equipment in his work:

• cotton suit;
• leather boots;
• combined gloves;
• goggles.

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

1.8. When taking on duty, the personnel are obliged to familiarize themselves with the entries in the log, check the serviceability of the equipment and all boilers installed in the boiler room, gas equipment, the serviceability of lighting and telephone.

The acceptance and handover of duty must be documented by the senior operator with an entry in the shift log indicating the results of checking the boilers and related equipment (pressure gauges, safety valves, nutritional devices, automation equipment and gas equipment).

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

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

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

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

1.13. 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.

1.14. 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.

1.15. 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.

1.16. Before closing hatches and manholes, it is necessary to check whether there are people or foreign objects inside the boiler.

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

1.18. Before the admission of people for repair work, the boiler must be turned off along all lines through which it can be put under pressure (main steam pipeline and its drains, feed lines, gas pipeline, periodic blowdown line).

1.19. A work permit was issued in two copies indicating the following security measures:

• plugs installed;
• the fan electric motor is de-energized and the poster "Do not turn it on - people are working!" is posted on the starter;
• lighting 12 V;
• work in overalls, safety shoes.

2. Preparing the boiler for kindling

2.1. Wear the prescribed clothing.

2.2. Before firing up the boiler, check:

• serviceability of the furnace and gas ducts, shut-off and control devices.
• serviceability of instrumentation, fittings, feeding devices, smoke exhausters and fans;
• serviceability of equipment for combustion of gaseous fuels;
• filling the boiler with water by starting the feed and circulation pumps;
• lack of plugs on the gas pipeline, nutrient materials, purge lines;
• the absence of people and foreign objects in the furnace;
• fill the boiler with water up to the ignition level mark.

2.3. Blow the gas pipeline through a purge candle, make sure that there are no gas leaks from gas pipelines, gas equipment and fittings by soaping.

2.4. Check on the pressure gauge that the pressure of the gas and air in front of the burners is consistent with the fan running.

2.5. Adjust the draft in the upper part of the furnace by setting the vacuum in the furnace to 2-3 mm of water column.

2.6. Ventilate the furnace and gas ducts for 10-15 minutes by turning on the smoke exhauster and fan.

3. Kindling the boiler

3.1. The kindling of the boiler should be carried out only if there is a written order in the shift log of the person responsible for the gas economy or the person replacing him. The order must indicate the duration of the kindling, the time, who is to carry out the kindling.

3.2. The kindling of the boiler must be carried out within the time set by the head of the boiler room, with low fire, reduced draft.

When kindling the boiler, it is necessary to ensure uniform heating of its parts.

3.3. The burner of a gaseous boiler must be ignited in the following sequence:

light the igniter and bring it into the mouth of the burner to be turned on, apply gas by slowly opening the valve (valve) in front of the burner and making sure that it immediately lights up, adjust the air supply, vacuum in the upper part of the furnace. if the flame goes out, stop the gas supply by closing the valves in front of the burner, open the purge candle, ventilate the furnace and start kindling according to the instructions;

When lighting the burner, one should not stand against the opening of the peepers, so as not to get burned from a flame accidentally thrown out of the furnace. The operator must be provided with safety goggles.

3.4. It is forbidden:

• ignite extinguished gas in the furnace without preliminary ventilation of the furnace and gas ducts;
• light a gas torch from a nearby burner.

3.5. When kindling, it is necessary to control the movement of the boiler elements during thermal expansion.

3.6. Monitor the water level in the upper drum of the boiler and the steam pressure on the manometer.

3.7. When steam begins to come out of the open air vent, it must be closed.

3.8. Tightening of bolts, hatches during the firing up of the boiler must be carried out with care, with wrenches without the use of extension levers in the presence of the person responsible for the operation of the boilers. This operation must be carried out at a pressure not exceeding 3 kg/cm2.

4. Putting the boiler into operation (main steam line)

4.1. Before putting the boiler into operation, the following operations must be carried out:

• check the serviceability of the pressure gauge, safety valve (by forced opening), water-indicating instruments (by purging them), with an entry in the logbook;
• check and put into operation safety automatics, regulation automatics;
• purge the lower points of the boiler.

4.2. The inclusion of the boiler in the steam pipeline should be done slowly, after thorough heating and purging of the steam pipeline. When warming up, it is necessary to monitor the serviceability of the steam pipeline, its compensators, supports and hangers. If water hammer occurs, stop heating and find out the cause.

4.3. Switching on is carried out at a pressure equal to the main steam line or lower by 0,5 atm.

4.4. The time of the start of kindling and turning on the boiler is recorded in the logbook.

5. Operation of the boiler

5.1. During duty, the boiler room personnel must monitor the health of the boiler (boilers) and all boiler room equipment, strictly observe the established mode of operation of the boiler in accordance with the developed and approved regime map. Faults detected during the operation of the equipment should be recorded in a shift log. Personnel must take corrective action. If it is impossible to eliminate the malfunctions on your own, then you must inform the head of the boiler room or the person responsible for the gas management of the boiler room.

5.2. 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 manometer (6-8 kg / cm2);
• for the operation of gas burners, maintaining normal parameters of gas and air, according to the regime map.

5.3. 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.

5.4. When working on gas fuel, to increase the load, you should constantly add first the gas supply, then air and adjust the draft.

To reduce - first reduce the air supply, then gas, and then adjust the vacuum.

5.5. If all or some of the burners go out during boiler operation, the gas supply to the burners should be immediately cut off, the furnace and burners ventilated, and the blow-off candle opened. Find out and eliminate the cause of the violation of the combustion regime and proceed with kindling according to the established scheme.

5.6. During the operation of the boiler, it is forbidden to caulk the seams, weld the elements of the boiler.

5.7. 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.

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 (drums, collectors, screen and boiler pipes), breaks, cracks, bulges.

6.8. With a decrease in vacuum less than 0,5 mm of water column.

6.9. When the torch of one of the burners goes out.

6.10. When the water flow through the boiler is below the set value.

6.11. When the temperature of the water behind the boiler rises above the set value.

6.12. When increasing and decreasing the pressure of gas and air in front of the burners.

6.13. When the power supply is interrupted.

6.14. 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:

• stop the supply of gas, air, open the purge candle (close the valves on the burners and the valves on the gas pipeline);
• 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 house 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.

7. Boiler stop

7.1. It is produced only on the written order of the boiler house responsible for the gas economy.

7.2. Gradually reducing the supply of air and gas, close the valve on the burner, open the purge candle and close the valve on the gas pipeline.

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

7.4. Ventilate the furnace and gas pipelines.

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

7.6. If there is no other boiler in operation, stop the circulation pump.

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

8. Final provisions

8.1. The administration of the enterprise should not give instructions to the personnel that are contrary to the instructions and may lead to an accident or an accident.

8.2. Workers are liable for violation of the instructions relating to the work they perform in the manner prescribed by the internal labor regulations and the criminal code of the Russian Federation.

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