8 BOILER OPERATION This section details the requirements for operating the boiler and the various regular checks and procedures that should be carried out on boiler systems. Employers must ensure that site-specific risk assessments are carried out for each boiler and site to determine: x the appropriate types of controls and limiters; and x the particular site manning and supervision levels to ensure that all risks remain as low as reasonably practicable. Additionally, all shell boilers must be examined and tested by the CP before first use (PSSR Reg 8 (3) c). 8.1 Boiler instructions Boiler instructions shall as a minimum include the following: x Instructions for the safe operation of steam boiler systems to comply with Regulation 11 of the Pressure Systems Safety Regulations, BS EN 12953-13, and the Pressure Equipment (Safety) Regulations; x The recommended daily checks required including water treatment plant performance and water quality test results; x How to warm through boiler systems starting from cold in a controlled manner, and add boilers to the range. Steam boilers shall be manned throughout the warming period and the water levels corrected to allow for expansion. The controls and limiters shall be tested prior to the boiler entering service; x Information on the safe systems of work, including appropriate standards of isolation that should be implemented for any work on the boiler systems; x How to protect off-line boilers against corrosion, freezing and sudden thermal shocks; x The requirement to notify any significant planned change in boiler operating conditions (e.g. reduction in operating pressure or increase in cyclic operation) to the Competent Person prior to making such change, so that the Written Scheme of Examination can be reviewed and, if necessary, amended to reflect the new operating regime. System re-starts following lock-out must only be made by a suitably experienced and competent boiler operator. Repeated attempts to re-start boiler plants must not be made except as part of a controlled fault identification process. 8.2 Recording of controls, limiters and water quality tests Clear, written instructions describing how and when to carry out routine tests must be kept on-site and be followed by suitably trained and competent boiler operators. Where the boiler controls may be operated off-site, under IEC 61508, these instructions must also be available at the point of control and operated by a person competent to do so. Routine testing of controls, limiters and water quality is essential to ensure continued safe, reliable and efficient operation. It can help prevent the following dangers: x Low water level which can expose the furnace or fire tubes and lead to metal overheating & catastrophic boiler failure; x High water level which can lead to priming of the boiler or carry-over of water, causing water-hammer, damage to valves and pipework as well as sudden steam leaks;
BG01 Guidance on the safe Operation of Steam Boilers Edition 2 – © 2019
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