Boilermaking Safety 34102-10 Notes Flashcards
Specific hazards
Can be dangerous if job specific hazards not recognized and avoided
Hazards-Extreme temperatures
Small boilers operate as low as 212F. Advanced steam generating boilers as high as 1,150F.
During construction extreme temps usually not an issue until initial operation and testing phases.
Many times, a boiler must be shut down, cooled down, and locked out prior to maintenance.
Sometimes this isn’t possible, and you must work on hot equipment. Appropriate PPE must be worn to protect from burns.
High temps can be measured with thermometer.
Hazards-Extreme pressures
Extreme pressures in day-to-day environment. Small package boilers operate as low as 15 psi. Large supercritical boilers contain steam pressures as high as 4500 psi.
Measured with pressure guage.
System may be depressurized for maintenance. Sometimes maintenance is performed with equipment under pressure. BM must be aware of pressure withing equipment he is working on. Must watch for areas of possible pressure release. BM must position themselves so they aren’t in danger. Research must be done to ensure people are protected during maintenance or construction.
Consider there may be multiple pressure sources in the system and all possibilities
Hazards-Combustion Residue Buildup
Combustion process produces many byproducts, most removed by emission control system. Remaining byproducts build up on the walls of the boiler in the form of solid combustion residue.
Hazards are:
Pieces can break loose and fall and injure personnel beneath
Dust produced when removing residue can render atmosphere unbreathable. ppe-clothing and supplied air
When it is heated with torch, toxic gases are given off. When cutting around residue, make sure there is adequate ventilation or supplied air
Hazards-Flammable/Combustible gases
Boiler is a confined space operating w/ different types of fuels during operation.
During maintenance, flammable and combustible gases may be present. Ventilation and atmospheric monitoring important. Be watchful during operations with open flames and sparks. Make sure combustible environment doesn’t exist around such work.
Crush hazards
Heavy and large components. Not much room to move around in internal structures. Combine these and conditions are hazardous.
Be aware of all rigging operations in your area. Especially important for inside work as there are few escape routes.
During rigging ensure weight of the load doesn’t exceed working load limit of equipment (including all: crane, chain hoist,slings, shackles, eyebolts etc) used for the lift.
All nonessential personnel to be evacuated from lift area until complete.
Try to determine all directions load may shift during rigging. Do not stand where you will be pinned or crushed. (time when crane hook not centered above skid pan and it shifted after leaving the ground)
Never turn your back on a suspended load-keep an eye on it and always have an escape route in mind
Hazards-Chemical Exposures
Boiler designed for maximum efficiency. Cleanliness of heat transfer surfaces contributes to this. Great pains taken to keep them clean. So boiler systems are flushed with caustic chemicals and cleaned with acids.
They can burn the skin and cause severe irritation to the eyes, mouth, and nasal passages.
Handling, storage and disposal of them are governed by law and site procedures.
Proper PPE must be worn-Proper clothing and respiratory protection.
Also hazardous chemicals used in plant process can vary. Hazards are often site specific, so you should know site specific procedures.
Hazards-Respiratory
Often BMs work in small, confined spaces where air is easily contaminated. Some materials in boiler construction also hazardous.
Hazards-Respiratory-Asbestos
Asbestos common before 1980s to insulate high temperature steam piping. Halted in 1981 due to extreme health risks. Existing asbestos used before slated for removal on as-needed basis and is still being removed.
Common uses before 1981:
Sprayed on fireproofing/insulation in buildings, insulation for pipes and boilers, wall and ceiling insulation, ceiling/floor tiles, putties, caulks, cements, brake linings/clutch pads, gaskets, boiler refractory, boiler door seals.
Asbestos signs may be posted in some areas.
Most common route for foreign material to enter the body is breathing. Asbestos generally not considered harmful unless dust fibers released in the air. Fibers can be trapped in mucous membrane and expelled. However some may pass deep into the lungs, or if they are swallowed they can be trapped in the body and cause serious problems.
Asbestos most dangerous when friable- meaning easily crumbled into fibers that can be airborne, such as spray on asbestos. Floor tile is not, unless ground with a power tool. Pipe and boiler insulation don’t present immediate hazard unless cloth lagging wrapped around outside is damaged so asbestos insulation is exposed to the air.
Since it has a reduced risk unless airborn, removal is scheduled on an as-needed basis, such as removal for maintenance. Still must be done by a trained asbestos removal crew.
Hazards-Rules to follow for asbestos
If insulation marked as containing asbestos, do not disturb or allow fibers to be airborne. Removal only to be done by qualified personnel.
If insulation not marked, treat it as asbestos until tested by qualified personnel. Any insulation installed after 1981 will be marked as asbestos-free. Insulation used prior may or may not be labeled. If not labeled asbestos-free, assume it has asbestos.
If insulation found to be exposed or damaged, take action to prevent fibers from being airborn, even if it doesn’t contain asbestos.
Asbestos free insulation usually marked. Many facilities use red or green band label to indicate. Everyone working with insulation should understand local marking system.
Hazards-Non asbestos Insulation
Asbestos free insulation has its own dangers.
Dust generated by cutting or grinding can irritate eyes and airways.
Guidelines-All insulation assumed to contain asbestos until proven otherwise
Short duration jobs wear dust respirator
Long term-wear disposable coveralls, gloves, shoe covers, head coverings to prevent fibers from being carried away from the job site-in addition to respiratory ppe.
Install and maintain in a way that reduces dust generation. Water mist, vacuum cleaners, plastic enclosures as needed.
Hazards-Lead Based Paint
Only a hazard when airborne
Ingestion can lead to: pregnancy difficulties, reproductive problems, high blood pressure, digestive problems, nerve disorders, memory and concentration problems, muscle and joint pain.
All paint should be treated as lead-based unless verified as otherwise. Non-lead based paint not labeled. You can contact the office to find where it might be. A simple test can determine if there is lead. If so, use proper respirator used. Before disturbing paint, survey the area and perform a safety briefing.
Hazards-Confined Space
BMs work in areas with limited entries and exits/ also with poor ventilation.
Worker entering confined space must take precautions.
Confined space-large enough to work in but limited means of entry or exit. Not designed for human occupancy, has limited ventilation.
Examples: Steam drums, precipitators, furnaces, penthouse, storage tanks, sumps, tank trucks, pits, trenches, large piping and ducts.
Associated hazards are: Structural failure, improper shoring, discharge of air, gas, water, or chemicals into the confined space; inadequate oxygen to support respiration, explosive atmospheres, inadequate lighting, presence of low quality air or toxic fumes.
Specific rules vary but must include:
Testing atmosphere for: adequate oxygen, or even excessive oxygen requiring ventilation or supplied air
Testing atmosphere for explosive content
Inspection of shoring and support
Issuance of entry permit with predetermined time limit for occupancy and expiration date and time.
Safety guard at entrance to ensure requirements are being met, also to act as a lifeguard to personnel within
Hazards-Welding related respiratory
Welding often fills area with toxic fumes and consume nearby oxygen supply. Can be overcome with adequate ventilation. Welding certain materials creates specific hazards.
Chromium, Lead, Cadmium, Beryllium: Produce highly toxic fumes when welded/brazed, and present extreme health hazards. Welder and surrounding workers must wear purified air breathing apparatus to provide source of clean breathing air.
Galvanized Metals: Metals coated with zinc to protect from weather. Fumes present respiratory hazard-zinc chills: flu like symptoms. Temporary with no long lasting side effects. Exposure should still be avoided proper ventilation and/or respirators.
Shielding Gas: Certain metals, stainless steel in particular, inert gas is used at the torch. Protects/shields arc and metal from oxygen. Common shielding gases are argon, carbon dioxide, and helium.
Problem: argon and carbon dioxide are heavier than air. Will sink and collect into pockets in low lying areas. Neither gas supports respiration. If welding using inert shielding gases, make sure to ventilate to ensure atmosphere is safe to breathe.
Hazards: Working at heights
Working at heights part of a BM’s job. Dangers are not only falls but falling objects on personnel working below.
Safety Harness: full body harness must be worn when working at any height greater than six feet. Harness must be attached to a 5,000 pound anchor point above the work area. Fall distance limited by OSHA to six feet.
Harness often the only thing preventing a serious fall. Should be inspected (lanyard webbing, straps, stitching, fraying, pulled/broken threads, abrasion, excessive wear, altered/missing straps, evidence of burns, heat, chemical exposure)(D-rings, snap hooks, buckles, adjusters, grommets-for deformation, fractures, cracks, corrosion, pitting, sharp edges, cuts, missing/loose parts, improper function) carefully before each use, and worn and fitted correctly.
1x year equipment must be inspected by a competent person, in addition to user inspection. If any of the above is discovered, harness must be removed from service and referred to authorized person for final disposal.
A harness that has experienced a fall must be removed from service.
