Boiler

143 Washington Avenue, Albany, New York 12210

Danny Donohue, President

CSEA OCCUPATIONAL SAFETY & HEALTH DEPARTMENT

S A F E T Y & H E A L T H

BoilerSafety

for Low Pressure and High Pressure Boilers

Produced through a grant from the New York State Department of LaborSafety and Health Training and Education Program, Grant #8506

2000 CSEA, Inc.

The information in this booklet has been compiled fromsources believed to be reliable and represents the bestcurrent opinion on the subject. No warranty, guarantee, orrepresentation is made by the Civil Service EmployeesAssociation, Inc. as to its absolute correctness or sufficiencyof any representation in this (and other publications), or thatother or additional measures may not be required underparticular or exceptional conditions or circumstances.

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Page

Introduction ............................................................................................................1

Boiler Safety ............................................................................................................2

Low Pressure Boilers (ICR #4)..................................................................................8

Boiler Inspections........................................................................................8Prohibited Installations ..............................................................................9Condemned Boilers and Components ........................................................11Stamping of Low Pressure Boilers..............................................................11Specific Requirements for Low Pressure Boilers ........................................11Installations, Repairs, and Replacements for Low Pressure Boilers ............16Heat Generating Apparatus - General Provisions ......................................19Heat Generating Apparatus - Special Provisions ........................................21Flame Safeguard Controls for Gas Fired Boilers ........................................24General Requirements for Oil Burners ......................................................24

High Pressure Boilers (ICR #14) ............................................................................27

Boiler Inspections......................................................................................27Repairs, Alterations and Miscellaneous Requirements ..............................32Riveted Repairs ........................................................................................32Re-rating and De-rating a Boiler ................................................................34Reinstallation of a Boiler ..........................................................................34Heating of Liquids ....................................................................................35Removal of Waste Gases from Boilers ........................................................35Power Boiler: New Installations ................................................................35Water Level Indicators ..............................................................................37Hydrostatic Tests ......................................................................................40Stamping of High Pressure Boilers ............................................................40Power Boilers: Existing Installations ........................................................40Safety Valves for Power Boilers ..................................................................40Fittings and Appliances ............................................................................41Miniature Boilers ......................................................................................42

Boiler Chemical Hazards........................................................................................44

Glossary ................................................................................................................46

NYS Dept. of Labor Boiler Safety Bureau Offices ..................................................48

NYS Dept. of Labor PESH Bureau Offices ..............................................................49

Federal OSHA Offices ............................................................................................51

1B O I L E R S A F E T Y

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Boilers can provide efficient and long-term heating applications for smallareas and for huge building complexes. Boilers are available in varioussizes and are designed for the buildings that they must heat.

Modern boiler technology has made boilers not only more efficient, butsafer as well. However, boilers are usually operated under high temperatures and pressures which, if not properly controlled, can causeexplosions with devastating affects.

A number of years ago in a telephone company building in New YorkCity, a boiler explosion occurred in the basement. Safety devices did notoperate properly and the boiler blew. The resulting explosion tore througha concrete wall and destroyed a switching room as well as above floor slabs.There was extensive damage and loss of life.

This booklet describes the important regulations that any employermust follow for both low and high pressure boilers to ensure the safety of operations. By using this booklet, employees can know whether or not the employer is following the guidelines for safe boiler operation andmaintenance procedures.

2BBOOIILLEERR SSAAFFEETTYY

Boiler Room Hazards

Following is a list of some of the hazards that can occur in a boiler room:

l Safety or safety relief valves that do not operate properly can cause a build-up of boiler pressure.

l Becoming asphyxiated or injured while cleaning boilers because properprocedures were not followed.

l Slippery floors due to inadequate clean-up of oil and grease spills.

l Improper storage of boiler chemicals.

l Asbestos insulation flaking off pipes and breeching.

l Working platforms and ladders not provided or in poor repair.

l Energy controlling devices such as switches, valves, etc. not being properlylocked and/or tagged out before working on equipment controlled by them.

l Leakage at gas and fuel supply lines.

l Flame failure, fuel cut-off, and other controls not working properly.

l Insufficient areas of clearance around boilers.

l Improper welding operations and repairs.

l Improperly placed exits that prevent egress of workers in the event of asteam leak or explosion.

l Unguarded pump shafts and unguarded nip points where belt and pulleysare in operation such as on air compressors.

These are just a few unsafe conditions that may be present. It isimportant that your employer maintain a safe worksite.

3Laws that Protect Boiler Operators andEmployees and Occupants in Buildings

Housing Boilers

If your employer has a low pressure boiler installation, the New YorkState Department of Labor Industrial Code Rule #4 (ICR #4) must befollowed. Low pressure boilers are steam boilers operating at 15 poundsper square inch (15 psi) or less and hot water boilers operating at pressuresnot exceeding 160 psi.

If your employer has a high pressure boiler installation, the New YorkState Department of Labor Industrial Code Rule #14 (ICR#14) must befollowed. These are boilers operating in excess of 15 psi.

The above code rules cover the regulations that outline safe boiler operations and are enforced by the New York State Department of LaborBoiler Safety Bureau. There are activities in a boiler room that may not becovered by these rules but will be covered by OSHA standards that areenforced by the New York State Department of Labor Public EmployeesSafety and Health (PESH) Bureau or by Federal OSHA for private sectoremployees. These standards describe the requirements for engineering andwork practice controls to reduce potential exposure to chemicals to belowthe permissible exposure limits (PEL), how welding must be safelyconducted, the guarding of machine tools, the requirements for lock-out/tag-out procedures, the use of personal protective equipment (PPE),especially respirators, etc.

Boiler room construction, exits, combustion air, emergency lighting, etc. are described in the New York State Uniform Fire Prevention and Building Code (UFC). This code is enforced by the agency or local code enforcement official.

Employers should be aware of these codes and must implement thenecessary safeguards.

GeneralFloors

Because of the nature of boiler room operations, floor surfaces must be easily cleanable. Floors should be of exposed concrete or other non-porous material. It is recommended that floors be sealed to prevent penetration of spills. OSHA standards require that every workroom floor be maintained in a clean and dry condition. Spills must be cleaned up immediately. Oil and grease spills should be absorbed in sand, diatomaceous earth or vermiculite and disposed of properly. Residues of oil and grease should be cleaned up using a grease and oil cutting detergent.

4Lighting

Boiler rooms should have adequate illumination. It is recommendedthat 100 foot-candles of illumination be provided. An inexpensive lightmeter can be used to determine light levels. It is important that dials,gauges, and controls be well illuminated. This is important so thatpotentially hazardous conditions can be noted and corrected.

If the boiler room is below grade and exceeds 2,000 square feet in area, the New York State Uniform Fire Prevention and Building Code requires emergency lighting so that attendants can safely leave the building. Emergency lighting is also recommended so necessary repairs to the boilers can be made during power outages. Lighting is required to stay on for at least 90 minutes. If more time is required, such as to work on boilers, it is recommended that a liquid petroleum gas generator be used. The NewYork State Uniform Fire Prevention and Building Code has requirementsfor emergency lighting.

Boiler Room Enclosures

The boiler room, if part of an occupied building, must be enclosed in fireresistive construction. The door(s) to the room, as well as door frames, must also be fire resistive. Both OSHA and the New York State UniformFire Code require fire resistive enclosures.

The room should be protected by either a sprinkler system, heat or smoke detection system or combination of these protections. Detection must be connected to a fire alarm system. Combustion air must be brought in from the outside and not from the interior of the building.

Emergencies

Emergency procedures must be in place so that employees assigned to the boiler room know what to do in the event of a fire or worker injury. OSHA requires that the employer establish emergency action plans to deal with these situations. Your employer should consult the appropriate OSHA standard for details.

Boilers as Confined Spaces

Boilers are considered confined spaces. When employees enter them to clean, repair, etc., the OSHA Permit-Required Confined Space Standardmust be followed by the employer. The employer must establish safe entry

5procedures. This includes an entry permit, attendant, written procedures, etc. Your employer should consult the OSHA Permit-Required ConfinedSpace Entry Standard.

If the boiler can be adequately ventilated so that any hazardousatmosphere is eliminated while workers are in the boiler and no otherhazards exist, the Permit-Required Confined Space Entry Standard does nothave to be followed.

Boiler Cleaning

When boilers are cleaned, the employer must provide for adequate ventilation by instituting engineering controls to keep any chemical exposure to a level below OSHA exposure limits. If engineering controls cannot be instituted, the employer must issue workers respirators appropriate for the chemical and exposure level in question. If respirators are to be worn, the OSHA Respirator Standard must be followed.

In cases where workers could be injured without the use of adequateprotective equipment, hard hats, heavy duty work gloves, eye protection,coveralls, etc. must be worn. This is required under the OSHA PersonalProtective Equipment Standard.

Before starting the cleaning, the Material Safety Data Sheets for the chemicals to be used in the boiler room cleaning process and for residues in the boiler should be reviewed for correct respirator selection, appropriate personal protective equipment, and precautions in handling.

Noise Exposure

Boiler room noise can be above 90 decibels (dB) which is above theOSHA permissible exposure limit for an eight hour day. If there is a noise problem, noise level readings should be obtained by your employer using a sound level meter. If noise levels are at or above 85 dB, averaged over eight hours, the employer must institute a hearing conservation program that complies with the OSHA Noise Standard.

If noise levels are at or above 90 dB averaged over eight hours, the employer must lower noise levels below 90 dB by using engineering or work practice controls. If these controls cannot be used, the workers must be provided with appropriate protective hearing equipment to wear.

6Boiler Chemicals

Chemicals are used in the boiler room to treat and test boiler water. Someof these chemicals are toxic and flammable. The employer must train employees in safe use, storage, etc. so that exposure is kept below the p e rmissible exposure limit (PEL). This is re q u i red by the OSHA Hazard Communication Standard and the New York State Right-to-Know Law.Material Safety Data Sheets (MSDS) for these chemicals must be provided bythe employer and kept at the worksite.

A list of typical boiler chemicals and their hazards is described in the Boiler Chemical Hazard s section of this booklet.

Storage of Chemicals

Flammable and combustible chemicals stored in small containers should bes t o red in Underwriters Laboratories (UL) or Factory Mutual (FM) appro v e dsafety cans. It is also recommended these cans be stored in UL or FMa p p roved flammable storage cabinets. Incompatible chemicals must not bes t o red together. Flammable chemicals must not be stored with either c o r rosives or oxidizers.

F i re resistive enclosures must be used to store 55 gallon drums. Drums offlammable materials must be grounded to a grounded building structure suchas structural steel, a rod driven into the ground, or a cold water pipe.

When filling a can from a drum, the can and the drum must be bonded together by a wire to prevent a static spark from igniting the flammablel i q u i d .

Both OSHA and the New York State Uniform Fire Prevention and BuildingCode limit the amount of flammable and combustible material that can besafely stored in designated are a s .

The employer is responsible for consulting these laws to ensure compliance.

E x p l o s i o n - P roof Tools and Equipment

T h e re should be no need for employees to use explosion-proof tools while inside the boiler if the employer has followed the Perm i t - R e q u i red Confined Space Standard. This not only includes OSHA re q u i rements c o n c e rning perm i t - re q u i red confined spaces but also the OSHA L o c k - O u t / Tag-Out Standard. During cleaning, maintenance, and when doubleblock-n-bleed is in use, there must not be any explosive atmospheres. No workshould be done in explosive atmospheres without the workers being speciallyt r a i n e d .

7Lock-out/Tag-out

When boilers are shut down for cleaning, maintenance or repair, all sources of energy initiation such as valves, switches, etc. must be locked out and/or tagged out. The employer is responsible for complying with theOSHA Lock-Out/Tag-Out Standard. This standard protects against injuryby locking and/or tagging out sources of energy while the equipment they control is being worked on. Residual pressure in steam pipes should be relieved and hot water remaining in pipes to be worked on should bedrained after lock-out. The locking and tagging of energy-producing devices includes using double block-n-bleed, capping, etc.

Asbestos

Many boiler rooms still have asbestos insulation covering pipes, boilers, domestic hot water heaters, expansion tanks, etc. Coverings should be inspected frequently to make sure there is no flaking or deterioration. If it is in disrepair, the employer should have it removed. All asbestos-containing materials (ACM) must be labeled as such. Asbestos exposure is regulated by New York State Industrial Code Rule #56 (ICR#56)and OSHA.

The New York State Department of Labor Asbestos Code Rule regulatesthe abatement of asbestos, whether done by in-house employees or by anoutside contractor. This code rule must be consulted before any abatementis carried out.

Industrial Code Rule #56 requires that workers removing asbestos, evenin small pipes or when doing boiler repair, must have a current New YorkState Asbestos Handlers Certificate and the workers employer must have a current New York State Department of Labor Asbestos ContractorsLicense.

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Boiler Inspections

Boilers must be inspected to make sure they are operating properly. This is necessary to protect not only the boiler attendants, but building occupants. If a boiler is operating properly, there is less danger of it exploding because of overpre s s u re.

G e n e r a l

Boilers must be inspected at least once a year by the New York State Department of Labor Boiler Inspection Bureau unless they are inspectedand insured by an authorized insurance company.

If a dangerous condition is noted, the Department of Labor will shut downthe boiler until the condition is corre c t e d .

Cast iron boilers must be inspected externally at least annually.

Steel boilers must be inspected externally at least annually.

Low pre s s u re steam boilers must be inspected internally at least every t h ree years. Hot water boilers must be inspected internally once every five years.

Certificate of Inspection

The certificate of inspection must be posted in the boiler room. If it is a portable boiler, the certificate of inspection must be posted on the inside of the cab or in a metal container and kept in the attached tool b o x .

The certificate must state the date of issuance and the maximum workingp re s s u re or temperature allowable until the next inspection.

P reparing a Boiler for Inspection

A boiler must be pre p a red prior to internal inspection or for hydrostatic testing. This includes a series of steps that involve drawing off water, removing plates and grates, removing brick work, stopping hot water or steam leaks into the boiler, etc.

9Employers Responsibility

The employer must provide a competent person to disassemble,reassemble, test, adjust, operate or handle any part of the boiler if it isrequired during the inspection. This person must be under the supervisionof the inspector. Because a boiler is under high pressure and temperature,anyone working on a boiler must understand its operation so that they canproperly assist the inspector.

Employers Notice

If there is any repair, reassembly or replacement to a boiler which if improperly done could create a hazard, the employer must notify the Department of Labor Boiler Inspection Bureau or insurance carrier so that it can be inspected.

Prohibited Installations

General

If a defective boiler is installed, it can endanger lives and property. If safety valves and other safety devices do not work, the boiler can become overpressurized and explode.

No person can knowingly install a defective boiler or boilercomponent.

No person can knowingly operate a defective boiler.

No person can knowingly operate a boiler at a pressure ortemperature exceeding the maximum allowable pressure or temperature.

Non-standard components

If replacement parts are used that are not parts originally installed by the manufacturer, they might not work with other original parts and unsafe conditions could result.

After March 31, 1965 the installation of non-standard components aspart of a boiler is prohibited. A non-standard part may be installed if it is designed so that it cannot cause the boiler to be defective and is approved by the boiler inspector.

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Second-hand boilers

If a used boiler is installed without having been inspected by theDepartment of Labor, there could be undetected defects that could causethe boiler to malfunction. This would create a hazardous condition.

Second-hand boilers cannot be installed in New York State without firstobtaining permission from the Department of Labor. After the boiler isinstalled, the Department of Labor or insurance company must inspect it.If an insurance company conducts the inspection, a copy of the report mustbe sent to the Department of Labor.

Boiler Operator

New York State law does not require a qualified person to be on duty atall times in the boiler room as long as the boilers are equipped withautomatic shut-down systems. It is recommended a qualified person be onduty during each shift. Every worker attending a boiler must be trained bythe employer so that the worker can operate the boiler safely.

The boiler operator must keep a log for each shift. The log must provide the following information:

l Blow-down of water column, sight glass and other safety equipment.

l Blow-down of mud drum and header.

l Record of water treatment.

l Test of safety valves.

l Record of any operating problems or deficiencies.

l Signature of the boiler operator.

The log must be available for the Department of Labor and insurancecompany inspector.

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Condemned Boilers and Components

General

If a boiler inspector finds a boiler or boiler components so defective that repair cannot be made, the Department of Labor has the authority tocondemn the boiler and have it immediately discontinued from service.

Stamping of Low Pressure Boilers

General

All low pressure boilers must be built in accordance with AmericanSociety of Mechanical Engineers (ASME) requirements by the manufacturer.The manufacturer must stamp an H on all boilers meeting ASMEspecifications. These specifications ensure that the boiler will operate safelyif proper procedures are followed.

Specific Requirements for Low Pressure Boilers

Safety valves for low pressure steam boilers

Safety valves are extremely important devices because they prevent pressure from building up in the boiler that could cause the boiler toexplode.

A low pressure steam boiler must have a safety valve or valves that will not allow steam pressure to rise more than 5 pounds per square inchgauge (5 psig) above the maximum allowable working pressure with allvalves open. This is with the steam generating equipment operating atmaximum.

If operating conditions change or additional boiler heating surfaces are installed, the valve capacity must be checked and increased if necessary to meet the new conditions.

Safety valves must be of the spring-pop type, adjusted and sealed to discharge at a pressure not to exceed 15 psig. The seats and disks must resist corrosion.

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No safety valve can be smaller than 3/4 inch nor larger than 4 1/2inches.

Some boilers, because of their increased capacity, will require two ormore safety valves.

Each safety valve must have a device that will lift the disk from its seat at least 1/16 inch when there is no pressure in the boiler.

Relief valves for low pressure hot water boilers

A low pressure hot water boiler must have a relief valve or valves that will not allow pressure to rise more than 20 percent above the maximum allowable working pressure if that is 30 psig or less; nor more than 10 percent if it is in excess of 30 psig. This is with the heat generating equipment operating at maximum pressure.

Note: Hot water boilers can operate up to 160 psi and still be considered low pressure.

Valve capacity must be checked and increased if necessary whenoperating conditions change or additional boiler heating surfaces areinstalled.

Relief valves must be of the spring-loaded type without disk guides onthe pressure side of the valve. The seats and disks must resist corrosion.

One required relief valve must be set to relieve at a pressure at or below the maximum allowable working pressure. It must be arranged so it cannot be reset to relieve at a higher pressure than the maximum allowable pressure. Additional valve or valves may be set to relieve at pressuresnot exceeding more than 20 percent of the lowest pressure to which any other valve is set.

Two or more relief valves may be required when boiler capacity is increased.

Each relief valve must have a device that will lift the disk fromits seat at least 1/16 inch when there is no pressure on the boiler.

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Installation and replacement of safety and relief valves for low pressure boilers

Valves must be in proper working order before the boiler is put inservice.

No person is permitted to load or tamper with valves to maintain apressure or temperature in excess of the maximum allowable pressure ortemperature stated on the inspection certificate.

Safety valves must be connected to boilers with the spindles vertical. Relief valves must be connected to the top of the boiler with the spindles vertical.

No shutoff can be installed between the safety or relief valve on the boiler nor on discharge pipes between such valves and the atmosphere.

Safety and relief valves must not be connected to an internal pipe in the boiler.

Discharge pipes for safety and relief valves

Discharge pipes enable the excessive steam and pressure to be safely discharged from the safety valve or relief valve. The pipe should discharge toward the floor to prevent scalding employees. Discharge of safety and relief valves must not present a scalding hazard to employees.

Gauges

Gauges are necessary on boilers so the attendants can make sure thatthe boiler is operating at its proper pressure.

A low pressure steam boiler must have the steam gauge connected to its steam space or water column or steam connection. The dial must be in one pound increments from zero to not less than 30 psig. The steam gaugemust be visible.

A low pressure hot water boiler must have the pressure or altitude gauge connected to it or to its flow connection. The gauge must be visible.

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Installation and replacement of steam gauges for low pressure boilers

Replacement must be in the same location as the factory installed gauge.

Water gauges

Water gauges tell the attendants what the water level is in the boiler. If the water level goes below the safe level, this creates a dangerous situation because pressures can build up above safe levels and cause an explosion.

Each steam boiler must have one or more water gauge glasses attachedto the water column or boiler by means of valved fittings. The lower fittingmust be fitted with a drain. The gauge must be accessible without the useof tools and must be visible.

Stop valves and check valves

Stop and check valves control the flow of water or steam between theboiler and the heat distribution piping. This enables the boiler to beisolated from the heat piping when repairs are necessary, etc.

If a steam or stop valve can close off the boiler from the heat distribution system, a check valve must be in the condensate return line between the boiler and the heat distribution system.

If a steam or stop valve can close off parts of the heat distribution system from one another, a check valve must be in the condensate return line.

Feedwater connections

Feedwater connections must be separate from any other connections. Feedwater connections for cast iron steam boilers, when connected from apressure line, must be made to the condensate return line or the condensate return pump reservoir. Feedwater connections cannot be madedirectly to the boiler.

A check valve must be in the feedwater line at the boiler for all boilers.

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Condensate level control

Each condensate return tank, when possible, must be provided with an automatic water level control set to maintain the water level within the limits of the glass. The boiler can only operate safely if the proper water level is maintained. An automatic control ensures this safe level.

Thermometers

Each hot water boiler must have a thermometer located and connectedwhere it can be easily read. The thermometer tells the attendant what the water temperature is. Excessively high temperatures could be dangerous to boiler operation.

Combustion regulators

Each automatically fired hot water boiler must be provided with a temperature-activated control at or near the boiler outlet which controlsthe rate of combustion to prevent the temperature of the water from risingabove 250 F.

Each automatically fired steam boiler must be provided with a pressure-actuated combustion control which operates to prevent steam pressure from rising above 15 psi. This control must not be able to be setto permit operation of the boiler if the temperature of the water is above250 F.

Bottom blow-off

Each boiler must have a blow-off pipe not less than 3/4 inch pipe size connected to the lowest water space. The blow-off is needed to clean the boiler of sludge and other dirt that could affect its operation.

Low water cutoffs

A low water cutoff is a device that protects the boiler by stopping its operation if the water level goes below the safe point.

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Each automatically fired steam or vapor system boiler, regardless of installation date and each automatically fired hot water boiler installed after January 1, 1966, must be equipped with a low water cutoff. It must cut off the fuel supply when the water level falls to the lowest safe water line. This lowest safe level cannot be lower than the lowest visible part of the water glass.

High limit controls

All hot water boilers installed after March 31, 1965 and boilers installed before that date which have new burners and controls, must have ahigh limit temperature-actuated control. It must automatically stop theboiler if the temperature of the boiler water at the boiler outlet rises to30 F above the maximum allowable working temperature.

All steam boilers installed after March 31, 1965 and boilers installed after that date which have new burners and controls must have a high limitpressure-actuated control. It must automatically stop the boiler if steampressure rises to 5 psig above the maximum allowable working pressure.

High limit controls must be installed in the electrical circuit controlling the boiler and it must stop the boiler from operating. It must operate regardless of the functioning of any other electrical device.

Installations, Repairs and Replacements of Low Pressure Boilers

General

The employer is responsible to make sure that any installation, repair, reassembly or replacement of a boiler component is done by competent persons. Installers and repairers must do such work in a safe and orderly manner. If repairs are done by persons not familiar with boilers, unsafe conditions could be created that could cause the boiler to explode.

Clearance around boilers installed before March 31, 1965

Adequate clearance around boilers enables workers to safely makerepairs and conduct inspections. If there is insufficient clearance, partscannot be inspected or repaired and workers could injure themselves.

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Sufficient clearance must be provided around any boiler so that proper operation, maintenance and inspection can be done.

Clearance around boilers installed after March 31, 1965 in a space not previously used to house a boiler

If the rated gross capacity of the boiler is less than 5 million BTU per hour, the clearance around the back and sides of the boiler must not be less than 24 inches. If the rated gross capacity of the boiler is more than 5 million BTU per hour, clearances around the back and sides of the boiler must not be less than 36 inches.

Clearances between boilers must not be less than 24 inches.

If the rated gross capacity is less than 5 million BTU per hour,clearances from the front wall or head of the boiler must not be less thanfour feet. If the rated gross capacity is more than 5 million BTU per hour,clearances from the front wall or head of the boiler must not be less thansix feet.

Working platforms that are installed on top of boilers must have a clearance of at least 7 feet from the platform working surface to overheadstructures.

Clearance around boilers installed after March 31, 1965 in a space or room that previously housed a boiler

Sufficient clearance must be provided around the sides and top of the boiler to allow for proper operation, maintenance and inspection. If a worker cannot get around the boiler without being hindered, the clearance is not sufficient.

Where it is necessary for a person to work on top of a boiler, the clearance between the top of the boiler and the underside of any overhead structure must not be less than three feet.

Working platforms and ladders for boilers installed after March 31, 1965

Platforms, ladders, and stairs must enable attendants to safely inspectand work on boilers. The worker must be protected from falling and musthave adequate working surfaces.

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Working platforms must not be less than 24 inches wide and must bemade of metal with a 4 inch metal toeboard. Railing must not be less than 42 inches high with a midrail and constructed of not less than 1 and 1/4 inch pipe.

Ladders must be made of metal and at least 18 inches wide between side rails.

Stairs must be made of metal and at least 24 inches wide. They musthave a railing not less than 42 inches high with a midrail. The railing mustbe made with at least 1 and 1/4 inch pipe.

Where the distance from the floor to the top of the boiler exceeds eight feet, a permanent stairway or ladder must be provided for safe access and exit from the top of the boiler. When more than two boilers are operated in battery, two remote means of exit from the boiler tops must be provided. One exit may be a vertical ladder.

When a main stop valve, safety valve or relief valve is located on top of a boiler, a permanent working platform must be installed to provide access. The working platform is not required if the top of the boiler is flat and provides an unobstructed walkway not less than 24 inches wide to thevalve.

Where a main stop valve is not located on top of the boiler and is more than 6 feet above the floor or nearest walkway, a permanent working platform must be installed.

Where the low point of a water column is located 10 feet or more abovethe floor or nearest walkway, a working platform must be installed toprovide access. A permanent ladder or stair need not be provided.

Where the bottom of clean-out openings on the side walls of a boiler setting are located 4 feet or more above the floor or nearest walkway, aworking platform must be installed to provide access. A permanent ladder or stair need not be provided.

Access for inspection for water tube boilers installed after March 31, 1965

A water tube boiler must be installed so that all drum heads (area where water circulates) are accessible for external inspection.

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Boiler room exits for boilers installed after March 31, 1965

Boilers installed in existing spaces or rooms which previously housed a boiler

The space must have at least one exit not less than 30 inches wide.If a door is provided, it must open in the direction of egress.

Boilers installed in new spaces or rooms

If the space is less than 300 square feet, it must be provided with at least one exit not less than 36 inches wide. If a door is provided, it must open in the direction of egress.

If the area is 300 square feet or more, two remote exits must beprovided. One of the exits must be at least 36 inches wide. If a door isprovided it must open in the direction of egress. The other exit may be apermanent vertical or inclined metal ladder not less than 18 inches widewhich accesses an opening not less than 36 inches wide. If the opening isprovided with a door, it must open in the direction of egress.

Boiler room exits for boilers installed before March 31, 1965

The space must be provided with at least one exit not less than 30inches wide. If a door is provided, it must open in the direction of egress.

Heat Generating Apparatus - General Provisions

Note: This section applies to all boilers regardless of date of installation.

Installation

Installation must be made to provide reasonable accessibility forcleaning heating surfaces, removing burners, replacing motors, controls,air filters, draft regulators and other working parts as well as for adjusting, cleaning, and lubricating parts.

Observation ports must be located to permit the operator to observeburner operations.

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Air supply for combustion

Combustion air sufficient for complete combustion of fuel is important. Incomplete combustion of the fuel could cause a build-up of lethal carbon monoxide. The resultant flame also becomes longer and more smokey.

Sufficient fresh air must be provided to allow for complete combustion of fuel at all firing rates. For gas or oil fired burners, the boiler room must have at least one square foot of opening for fresh air entry for every 2 million BTU of fuel burned per hour.

Combustion air must not be supplied from inside the building. It mustbe supplied using outside air with the intake located on an outside wall. If the intake were to be located inside of the building, the wall might notcontain a boiler explosion. This would endanger the building occupants.By being on the outside wall, the force of the explosion would be to theoutside away from the building. This is also required by the New York StateUniform Fire Prevention and Building Code.

Maintenance

All equipment must be maintained in good condition.

Safety controls must be properly adjusted and maintained.

All machinery must be guarded in compliance with OSHA standards.

Electrical equipment and wiring

Installation of electrical equipment must be neat and orderly. Wiringmust be properly supported and protected. All wiring and equipment mustbe installed in compliance with OSHA standards and the National ElectricCode (NEC).

Spliced conductors and uninsulated metal parts having a potential of over 30 volts must be installed in enclosers requiring tools for entry. Strain relief must be provided on conductors leaving enclosures. This prevents the insulation on the wires from tearing.

When wires not in wireways (metal conduit) pass through metal walls,they must be protected by bushings, metal grommets or by smoothing ofthe hole the wires pass through. This is required to prevent abrasion of thewires.

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Detachable plug connectors cannot be used in circuits wheredisconnection or connection of the circuit could allow for unsafe operation.

Service connections, including those in low voltage non-safety circuits, which need to be broken to service controls, must be made in such amanner that they can be connected and reconnected without breaking asoldered connection or breaking or cutting wires.

Heat Generating Apparatus - Special Provisions

Note: The provisions of this section apply to boilers installed after March 31, 1965.

Control circuits

Electrical circuits must be installed so the boilers and any safety devices operate properly. They must also be installed to protect attendants from shock and electrocution.

Control circuits must be 2 wire with the neutral grounded. The circuit must have a nominal voltage of 150 volts or less. The circuit must be fused with the fuse rating not greater than the electrical components ofthe circuit. Safety controls or protective devices must cut off power tohot (ungrounded) conductors. Safety controls must go to the off positionwithout needing electricity. They can operate by pressure, temperature, low water fuel cut-off, flame failure, oil and gas fuel shutoff valve control, air and fuel interlock controls or feedwater regulating controls.

Heat generating apparatus fired with pulverized controls

Explosion vents extending to the outside air must be installed on storage bins, cyclone collectors, and piping for central storage systems of pulverized coal.

To ignite pulverized coal, a large and stable pilot flame to ensure proper ignition must be provided. Ignition must be by oil or gas. Oil-soaked torch ignition is not permitted.

A supply of dry coal must be used to ignite the boiler.

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Mechanical and electrical interlocks must be provided on induced (1)draft fans, (2) forced draft fans, (3) primary oil blowers, (4) coalpulverizers and (5) coal feeders. They must shut down in the order indicated.

A flue damper interlock must be provided if natural draft is used instead of induced draft (draft produced by a fan). This is to ensure that the flue damper is wide open in case of failure of the forced draft fan.

A central storage interlock is required on conveyers, pulverizer motorand blowers, and separate blowers if a central storage system is used. The interlocks must automatically shut down all units ahead of a single unit to avoid coal from piling up in the system.

Gas burners

All controls must be accessible for normal servicing and adjustmentand be replaceable during normal servicing.

All parts of the burner that come in contact with the operator during adjustment or servicing must be free of sharp projections, edges or projecting screwheads.

Compartments having gas piping controls must be ventilated.

Pilot installation

Pilot lights are important because they ignite the fuel that produces hot water or steam. If they do not operate properly, excessive fuel or gas can get into the boiler which could cause an explosion when ignition is restarted.

Pilot lights must be able to be seen with the main burners on or off.

Pilot lights must be located so they cannot be obstructed by falling scale or dirt.

If an enclosed fire box is used, there must be an adequate air supply for combustion of the gas for the pilot.

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Gas valves

Lubricants used on gas valves must be resistant to liquified petroleumgas.

There must be a manual pilot shutoff to turn the gas supply to the pilot burner on and off.

A manual emergency gas shutoff valve, marked and accessible, must be provided for closing off the gas supply in case of fire.

Gas supply lines

Gas piping, tubing and fittings must be securely supported with suitable pipe hooks, metal pipe straps, bands or hangers. Gas piping cannot be supported by other piping. If the other piping breaks, the gas lines could also break. Also, the other pipes could contain material that could react with the gas to create a fire or explosion.

Compounds used on threaded joints of gas piping must be resistant toliquified petroleum gases.

Connections for pilot gas supply lines must be located so that the tubingand pilot valve are protected from damage.

Draft hoods

There must be a firm support of flue piping either to the flue outlet or draft hood (if a built-in draft hood is provided).

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Flame Safeguard Controls for Gas-Fired Boilers

Note: The provisions of this section apply to all gas-fired boilers without regard to date of installation.

Flame guard devices

All gas-fired boilers must be equipped with adequate flame safeguard devices.

Pilot or torch reliability

On manually lighted or automatically ignited gas-fired boilers, thepilot or torch must be at the proper location to ignite the main burnerbefore an electrical circuit opens the main burner gas valve.

Burner flame failure controls

The main gas valve must close automatically within 90 seconds of flame failure for burners with an input rating of less than 400,000 BTU.

For burners with an input rating of 400,000 BTU or more, the electrical circuit to the main fuel valve must automatically de-energize within 4 seconds after flame failure and the de-energized valve must automatically close within the next 5 seconds.

General Requirements for Oil Burners

Note: The provisions of this section apply to all oil burners regardless of date of installation.

Controls

All controls must be available for servicing and adjustment in positionand must be replaceable during normal servicing.

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Safety controls for abnormal oil discharge

Burners must be equipped with automatic primary safety controls toprevent abnormal discharge of oil at the burner in case of ignition or flame failure.

Sharp edges

Parts of the burner that may come in contact with the operator during normal usage must be free from sharp edges, projections and projecting screwheads or ends.

Locking adjustable parts

Adjustable and moving parts must be locked to prevent shifting.

Strainers

Small orifices in oil supply systems likely to become clogged must be protected by a suitable strainer.

Fittings and piping

Tubing must be protected from damage. When pipe are disconnected,dripping oil must be kept away from moving parts.

Breakable gauges

A glass gauge or sight feed cannot be used if its breakage could release fuel oil from the system.

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Flame Safeguard Control Requirements for AllOil Burners Installed Before March 31, 1965

Pilot light reliability

Automatic oil-fired boilers must have a reliable pilot light that comes on within 15 seconds. This is necessary to prevent excessive gas from leaking out, which could cause an explosion if ignited. The main oil valve mustopen only after the pilot light comes on so that the oil will be ignited. If thepilot light was not on and the oil came out, there would be a flood of oil which, if ignited, could cause an explosion or fire.

On any burners equipped with a reliable pilot light, if the pilot light does not ignite the fuel within 60 seconds, the fuel must stop flowing. This prevents a flood of fuel which, as previously mentioned, can cause an explosion or fire if ignited. The electrical circuit must auto-de-energize the fuel valve to stop the flow of oil to the burner.

Flame Safeguard Control Requirements for AllOil Burners Installed After March 31, 1965

Pilot lights

Burners must be equipped with a reliable pilot light to make sure fuel is properly burned. The burner must open up only after the pilot light is onso that unburned fuel which could cause a fire or explosion does notaccumulate.

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HHIIGGHH PPRREESSSSUURREE BBOOIILLEERRSS -- IINNDDUUSSTTRRIIAALL CCOODDEE RRUULLEE ##1144 (( IICCRR ##1144))

Boiler InspectionsGeneral

High pressure boilers operate at higher pressures and temperaturesthan low pressure boilers. The requirements for inspection of high pressureboilers are more strict than for low pressure boilers.

High pressure steam boilers must be inspected internally and externallyat least yearly. The external inspection must be made approximately six months after each internal inspection.

High pressure hot water boilers must be inspected internally at leastevery three years. If equipped with manholes and handholes, an annualinternal inspection is required. An external inspection must be made oncea year approximately six months after each internal inspection.

Inspection preparation

The employer must prepare the boiler for inspection. There is a series of steps that must be taken to make sure the boiler is properly inspected. These steps include drawing off water, removing plates and grates,removing brickwork, stopping all leaks into the boiler, etc.

Insurance inspections

If boiler inspections are made by an authorized insurance company, inspections do not have to be made by the New York State Department ofLabor.

Certificate of inspection

A Certificate of Inspection will be issued by the Department of Labor that indicates the boiler meets the requirements of this industrial code rule and that it is safe to operate. A boiler cannot be legally operated without this certificate.

The certificate must be posted under glass in the boiler room. The

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certificate for portable boilers must be on the premises where the boileris being operated and must be available at all times.

No boiler can be operated at a pressure in excess of the allowableworking pressure specified on the latest Certificate of Inspection.

If steam pressure has to be increased above the allowable workingpressure specified in the Certificate of Inspection, the Department of Labormust be notified and a new certificate is required.

Safety appliances

Safety appliances are important devices on high pressure boilers. They prevent build-up of pressures and temperatures that could cause the boiler to explode.

No one is permitted to tamper with any safety valve.

No one is permitted to load the safety valve to a greater pressure than allowed by the Certificate of Inspection.

Numbers on boilers

No one is permitted to deface any number on a boiler or a Certificate of Inspection. Only an inspector can change numbers or certificates.

Defective boilers

A boiler with any defect that affects its safety must be taken out of serviceand the Department of Labor and insurance company must be notified.

Condemned boilers

A boiler that is condemned must immediately be taken out of service.It must have a stamp stating: CONDEMNED N.Y. STATE D. OF L.

Cancellation of Certificate

At any time after the issuance of a Certificate of Inspection, it may be removed and cancelled by the Department of Labor or the inspecting authority when an inspection finds the boiler is defective or that the owner permits the boiler to be improperly operated.

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Platforms, ladders, and exits

Platforms, ladders and exits enable boiler room attendants to access boilers for repair, inspection and maintenance and to safely exit the boiler room during emergencies. If they are not properly designed or safe, the workers could be endangered when climbing on boilers or exiting the boiler room.

Platforms must be constructed of metal and be not less than 24 incheswide. They also must have a 4-inch toeboard and a 42-inch high railingwith a midrail.

Ladders must be at least 24 inches wide between side rails.

Stairs must be at least 24 inches wide and provided with hand rails.

When the distance from the floor to the top of the boiler exceeds eight feet, a permanent ladder must be provided.

When two or more boilers are operated in battery, two means of access remote from each other must be provided.

A permanent platform must be provided to gain access to the main stop valve.

All boilers must be provided with platforms at clean out openings whenthe openings are over four feet above the floor.

Wherever an employee can be trapped, two means of escape remote fromeach other must be provided.

Blow-off tanks

When sludge and other impurities are blown out of a boiler that operates above 100 psi, they must be discharged to a blow-off tank so the discharge does not strike attendants.

Boiler operator

Persons attending a boiler must have sufficient training so they canoperate the boiler in a safe and efficient manner.

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The boiler operator must keep a log for each shift. The log must contain the following information:

l Blow-down of water column, sight glass and other safety equipment.

l Blow-down of mud drum and boilers. The mud drum is the bottom of the header area where the water circulates.

l Record of water treatment.

l Test of safety valves.

l Record of any operating problems or deficiencies.

l Signature of boiler operator.

The log must be available for inspection by the State boiler inspector and insurance inspector.

Mechanical fuel and feed

Low water cutoff must be provided on all boilers with gas, oil or mechanical firing. Low water cutoff prevents the boiler from operating when the water level in the boiler is below the safe point. If there isnot enough water in the boiler and it continues to operate, it could causean overpressure. If safety devices do not work, there could be an explosion.

Electric switches must be able to withstand atmospheric deteriorationand must be approved by the Underwriters Laboratories (UL). They mustbe accessible for inspection, cleaning, and repairing.

Maximum allowable working pressure

The maximum allowable working pressure of a power boiler must bedetermined in accordance with the American Society of MechanicalEngineers (ASME) Code.

Pressure controls

Each automatically fired steam power boiler must have at least onesteam pressure control device that shuts off the fuel supply to each boilerwhen the steam pressure reaches a preset maximum operating pressure.

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This prevents the fuel from continuing to be fed into the boiler which could cause pressure build-up above safe levels.

Each automatically fired steam power boiler must also have a high limit manual reset steam pressure control that prevents generation of steam in excess of the maximum allowable working pressure.

Accident notification

When an accident occurs that results in injury or in property damage in excess of $1,000, the owner or operator of the boiler must report the accident to the Department of Labor within 24 hours. If the accident results in death or property damage in excess of $25,000, the report must be given immediately via telephone and confirmed via mail within 24 hours.

In cases of death, it must also be reported immediately to theappropriate district office of the Department of Labor Public EmployeeSafety and Health (PESH) Bureau by the employer. Injuries, illnesses anddeaths must be recorded on the annual DOSH 900 log by the employer.

Boiler clearances

It is important that boilers have sufficient clearances around the sides, back, and front. This is necessary so boiler room employees can safely inspect, maintain, and repair the boiler.

Boilers must have a minimum clearance of 24 inches from walls orpartitions for care and inspection.

A clearance of 7 feet must be maintained from the working platform tothe underside of any overhead structure where it is necessary to go on topof the boiler for maintenance purposes. The clearance must be at least 3feet and there must be a clearance of at least 6 inches from the highestpoint of any valve to the underside of any overhead structure when theboiler is installed in an existing building.

Preparing boilers for hydrostatic testing

Hydrostatic testing involves putting the boiler under water pressure to make sure that all welds, joints, and tube connections are tight. Before a boiler is tested, the employer must follow a series of steps as described in the boiler code.

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Repairs, Alterations, and Miscellaneous Requirements

Repairs and Alterations

If repairs are not done properly, especially welded repairs, the strength of parts could be undermined and not be able to withstand the operating pressures. If this happens, parts can fail causing explosions.

Welded repairs or alterations must be completed in accordance with the Department of Labor requirements.

The organization making the repairs or alterations is responsible for inspection, documentation, and certification of the work and for obtaining approval for work procedures prior to the work being done. The approval must be obtained from the insurance company or the Department of Labor.

Materials

Materials used in making welding repairs or alterations must conform tothe ASME Code.

General rules for repairs

Repairs to boilers must only be performed by an organization thatpossesses a valid National Board or New York State Repair Certificate of Authorization and/or a valid ASME Certificate of Authorization.

Repairs include welded repairs or replacements of pressure parts, tube sheets and tubes, pressure retaining parts, replacement or addition of nozzles, installation of patches, welding of rivets, replacement of sections by welding, etc. Routine repairs include addition of non-pressureparts to pressure parts, weld build-up of worn areas, replacement of boilertubes, replacement of nozzles, change in arrangement of tubes in furnace walls, economizer or superheater sections, etc.

Note: The code rule must be consulted for exception to repairs.

General rules of alterations

Alterations include increasing allowable working pressure, additions of

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new nozzles or openings, increase in heating surface, replacement of apressure part, or a decrease in minimum temperature.

Note: The code rule must be consulted for exceptions to alterations.

Alterations for boilers, with the exception of re-rating, must be done in accordance with the National Board Inspection Code.

Alterations to boilers must be done by an organization that holds anASME Symbol Stamp listed in the ASME Code. The work involved must bewithin the scope of the ASME Code Symbol Stampholders Certificate ofAuthorization.

The stamping or attaching of a nameplate to a boiler indicates that the alterations were carried out in compliance with the code. This stamping or attaching of the nameplate can only be done with the knowledge of the inspector.

After alteration, the boiler must be pressure-tested.

Welders

The party undertaking repairs or alterations is responsible for preparing welding procedure specifications and conducting tests. Before welding is done, the inspector must review the procedures and tests. A copy of the welders qualifications must be kept at the job site.

Wasted areas

Wasted areas (areas where the metal has thinned due to wear)may be built up by welding providing that the inspector judges that thestrength of the structure will not be impaired. Welding build-up of repair isnot permitted on rivet heads, brace ends, attachments to braces, and onpitted or corroded areas of unbraced surfaces.

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RREE--RRAATTIINNGG AANNDD DDEE--RRAATTIINNGG AA BBOOIILLEERR

Re-rating

A boiler is re-rated when its maximum allowable pressure ortemperature is increased or minimum temperature is decreased, requiringadditional testing. Re-rating can only be done if it is established inaccordance with the ASME Code, inspection records verify the boiler issatisfactory for the new conditions, the re-rating is acceptable to theinspector, and the boiler is pressure-tested for the new rating.

De-rating

A boiler is de-rated when its maximum allowable pressure is decreased.De-rating can only be done after the procedures as described under re-rating are done.

After de-rating, a nameplate must be attached witnessed by theinspector.

RREEIINNSSTTAALLLLAATTIIOONN OOFF BBOOIILLEERRSS

General

Any boiler operated in New York State prior to January 1, 1918, or any boiler changing location within the State may be installed, provided an Application for Permission to Install a Second-Hand Boiler is filed with the Department of Labor and permission is granted.

The boiler must be thoroughly inspected inside and out and ahydrostatic pressure test applied if required by the inspector. A Certificateof Inspection will be issued if the boiler is safe.

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Heating of Liquids

A heater for liquid fuels or other liquids harmful to the boiler cannot be installed directly in the steam or water space of the boiler. The fuels or other harmful liquids could cause a weakening in boiler parts which could cause an explosion.

When an external heater is used, means must be provided to preventliquid fuels or other harmful liquids from getting into the boiler.

Removal of Waste Gases From Boilers

Means of exhaust

All boilers must be equipped with a means of exhausting the products of combustion to a safe place in the outside atmosphere. This is done byexhausting the smoke out through a properly designed chimney.

Power Boilers: New Installations

A power boiler is a steam or vapor boiler operating above 15 psig and exceeding miniature boiler size. This includes hot water heating or hot water supply boilers operating above 160 psi or 250 F. Because these boilers operate at high pressures and temperatures, they require special attention by the employer. Power boilers can cause extensive damage if they explode.

Access and inspection openings

All boilers must be provided with suitable inspection openings for examination or cleaning.

Safety valves and safety relief valves

Each boiler must have at least one safety valve. If it has more than 500square feet of bare tube water heating surface, or if an electric boiler has a power input more than 1100 watts, it must have two or more safety valves or safety relief valves.

One or more safety valves or safety relief valves must be set at or below the maximum allowable working pressure.

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When two or more boilers which are allowed different pressures are connected to a common steam main, all safety valves must be set at a pressure not exceeding the lowest pressure allowed.

Safety valve and safety relief valve testing and repair

Valves on power boilers with a maximum allowable working pressure upto 400 psi must be manually tested not less than once a month andpressure-tested once a year. Valves on power boilers with a maximumallowable working pressure over 400 psi must be pressure-tested once eachyear.

Repairs of safety valves and safety relief valves must be done by the valve manufacturer. If the manufacturer does not repair the valve, it must be repaired by an organization that possesses a current National Board VR Certificate of Authorization.

Each safety valve or safety relief valve must bear a stamp from the manufacturer that indicates the name of the manufacturer, design or type number, pipe size of inlet, pressure at which it blows, year built, capacity, capacity of lift, and ASME symbol.

Safety valve connections

The safety valves or safety relief valves must be connected to the boiler independent of any other steam connection, and attached as close as possible to the boiler or normal steam flow path, without any unnecessaryintervening pipe or fitting.

All safety valve or safety relief valve discharges must be located orpiped so the discharge is away from running boards or platforms.

Discharge piping from safety relief valves on high temperature water boilers must be provided with provision for water drainage and steam venting. Cast iron valves for high temperature water boilers areprohibited.

The discharge of safety valves and safety relief valves must be located to prevent scalding.

When a valve is exposed to the outdoors, it may have a cover forprotection providing the cover does not interfere with its operation.

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Safety valve construction

All safety valves must be constructed so that the failure of any part cannot prevent the free and full discharge of steam from the valve.

Superheater safety valves

A superheater is a device that heats the water or steam to a higher temperature after it leaves the boiler. It is an energy-saving device because it reduces the amount of steam the boiler has to produce.

Every superheater must have one or more safety valves near the outlet.

Reheater valves

A reheater is a device that heats steam to its original superheated temperature. It works the same way as a superheater and is an energy-saving device by reducing the amount of steam the boiler has to produce.

Every reheater must have one or more safety valves. At least one valve must be located in the steam flow path between the reheater outlet and the first stop valve.

Outlet connections

Every boiler must have proper outlet connections for the required safety valve(s).

Water Level Indicators

Water gauge glasses

Water gauge glasses are important on boilers because they show what the safe water level should be. If water levels go below safe levels, theboiler can malfunction causing overheating damage.

Each boiler must have at least one water gauge glass.

Boilers operating at pressures over 400 psi must have two water gauge glasses.

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The lowest visible part of the water gauge glass must be at least two inches above the lowest permissible water level.

Shutoff valve

Each water glass must be equipped with a top and bottom shutoff valve.

Gauge cocks

Gauge cocks are a check on the water gauge or a temporary means of determining water levels when a gauge glass breaks or if a gauge is plugged.

Each boiler must have three or more gauge cocks located within thevisible length of the water glass.

Pressure and temperature gauges

It is important that boiler attendants know the pressure in the boiler at all times. Boilers can then be shut down when pressures exceed safe levels.

Each boiler must have a pressure gauge so located that it is easily readable. The gauge must be installed so it reads the pressure in the boiler at all times.

Each high temperature water boiler must have a temperature gauge solocated and connected that it is easily readable. The gauge must beinstalled so that it indicates the temperature in the boiler at all times.

Inspectors test gauge connection

Each boiler must be provided with a valved connection for the purpose of testing the accuracy of the boiler steam gauge.

Stop valves (the stop valve controls the flow of steam)

Each steam discharge outlet, except for safety valves or safety reliefvalves or reheater inlet or outlet connections, must be fitted with a stopvalve. The stop valve controls the flow of steam.

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Steam mains

Steam mains connected to boilers must be anchored at suitable points to allow for their expansion and contraction. If steam mains are not properly supported, they could break and spread superheated steam over the boiler room.

Superheater drains

Each superheater must be equipped with at least one drain.

Blow-off piping

Each boiler, except as noted in this code, must have a bottom blow-off outlet in direct connection with the lowest water space. This enablesthe boiler operators to clean the boiler of sludge and other contaminants. The pipe must be able to be inspected.

It must be located to prevent scalding. The bottom blow-off valves mustbe tested daily when the boiler is in operation.

Requirements for drains

Drains must be provided in the boiler system wherever water will collect.

Feedwater supply

Feedwater is the water that goes into the boiler to maintain its safe water level so that steam or heated water can continually be heated and distributed safely.

High temperature water boilers must be provided with means of addingwater to the boiler system while under pressure. Feedwater pipe must beprovided with stop and check valves so the supply can be shut off to theboiler when there is an emergency.

Gravity feed return

When return water is fed back to the boiler by gravity (not by pumps), there must be stop and check valves in the return line. This is necessary to shut off the return supply when there is an emergency.

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Hydrostatic Tests

After a boiler has been completed, it must be subjected to a hydrostatic test to make sure it can operate safely within the maximum allowable pressure.

Stamping of High Pressure Boilers

Stamping

When a boiler is completed, it must have all the required stamps affixedso they are clearly visible. This shows that the boiler is safe to operate at the rated maximum allowable working pressure.

Power Boilers: Existing Installations

Maximum allowable working pressures

Factors of safety

A safety factor is the ratio of the ultimate maximum allowable working pressure to the actual permissible allowable working pressure. The older the boiler, the higher the assigned safety factor to provide for a greatersafety margin. Boiler safety factors vary from 5 to 7. If a boiler has apermissible allowable working pressure of 100 psi (the pressure indicated on the certificate) and a safety factor of 5, it means the boiler can takepressures up to 500 psi without blowing. It must never operate above 100 psi but if there was a sudden increase in pressure, it could safely handle up to 500 psi. This gives the boiler attendants time to shut downthe system or get to a safe area.

Safety Valves for Power Boilers

Required safety valves

The safety valve capacity of each boiler must be such that the valves will discharge all the steam that can be generated by the boiler without

41

allowing the pressure to rise more than 6 percent above the maximum allowable working pressure or more than 6 percent above the highest pressure to which the valve is set.

One or more safety valves on every boiler must be set at or below the maximum allowable working pressure. When additional valves are added,they must conform to the code rule.

Safety valves must be placed as close to the boiler as possible. No valve of any kind can be placed between the safety valve and the boiler nor on the discharge pipe between the safety valve and the atmosphere.

Fittings and Appliances

Water glasses and gauge cocks

Each steam boiler must have at least one water glass.

Each boiler must have three or more gauge cocks, located within therange of the visible length of the water glass, when the maximum allowable working pressure exceeds 15 psi, except as noted in the code rule.

Steam gauges

Each boiler must have a steam gauge connected to the steam space or tothe water column or to the steam connection.

Stop valve

Each steam outlet from a power boiler (except safety valve connections) must be fitted with a stop valve located as close to the boiler as possible so steam can be shut off during emergencies.

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Miniature Boilers

A miniature boiler by definition cannot exceed the following limits:

l 16 inches inside diameter of shell;

l 5 cubic feet gross volume, exclusive of casing and insulation;

l 20 square feet water heating surface;

l 100 psi maximum allowable working pressure.

Pump or feed device

Each miniature boiler must be provided with a pumping device to feedwater to the boiler to insure the water level in the boiler is maintained atsafe levels. It must also be provided with feedwater and blow-offconnections.

Water gauge and water level

Each miniature boiler with a definite water level must be equipped witha glass water gauge for determining water level.

Steam gauge

Each miniature boiler must be equipped with a steam gauge.

Safety valves

Each miniature boiler must be equipped with a safety valve. The safety valve must be connected to the boiler separately from any other steam connection, without any unnecessary intervening pipe or fitting.

Stop valve on steam line

Each steam line from a miniature boiler must be provided with a stopvalve located as close to the boiler shell or drum as practicable.

Fuel regulating governor

It is recommended that all boilers operated with gas, oil, or mechanical firing be provided with an automatic low water fuel cutout and/or with an automatic fuel regulating governor controlled by the steam pressure. The governor stops the flow of fuel to the boiler when the boiler pressure goes above safe levels.

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BBOOIILLEERRCCHHEEMMIICCAALLHHAAZZAARRDDSS

CHEMICAL HEALTH FIRE or EXPLOSION PROTECTIVEHAZARD HAZARD MEASURES

K E Y:{

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CHEMICAL HEALTH FIRE or EXPLOSION PROTECTIVEHAZARD HAZARD MEASURES

45

46

GGLLOOSSSSAARRYY

Alteration: Change in a boiler that substantially alters the original design andthat requires consideration of the affect of the change on the originaldesign.

ASME Code: Boiler and pressure vessel code published by the AmericanSociety of Mechanical Engineers.

Boiler: A closed vessel in which steam is generated, water is heated, steam issuperheated, or any combination thereof, under pressure or vacuum foruse external to itself by the application of heat from combustible fuels,electricity, or any other source.

Condemned: A boiler declared unsafe and having an applied stampingdesignating it as condemned.

Defective Boiler: A boiler not provided with all the required controls anddevices in operating order.

Department of Labor: New York State agency responsible for enforcingIndustrial Code Rules #4 and #14. This is done through the BoilerSafety Bureau.

External Inspection: An inspection made while the boiler is in operation.

High Temperature Water Boiler: A boiler completely filled with waterintended for operation at pressures in excess of 160 psi at temperaturesin excess of 250 degrees F.

Hot Water Heating Boiler: A boiler completely filled with water that furnisheshot water to be used externally to itself at pressures not exceeding 160psi at temperatures not exceeding 250 degrees F at or near the boileroutlet.

Inspector: A boiler inspector who holds a valid certificate of competencyissued by the Department of Labor Boiler Safety Bureau.

Low Pressure Boiler: A boiler producing steam or vapor at a gauge pressureof 15 psi or less, or producing hot water at a gauge pressure notexceeding 160 psi, or at a temperature not exceeding 250 degrees F.

Maximum Allowable Working Pressure: The maximum gauge pressurepermissible at the top of a completed vessel in its operating position for adesignated temperature.

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Maximum Allowable Working Temperature: The maximum temperature ator near the outlet of a hot water boiler, in degrees F, at which the boilermay be safely operated.

Miniature Boiler: A power boiler or high temperature water boiler that doesnot exceed 16 inches inside shell diameter; does not exceed 20 squarefeet of heating surface, except for electric boilers; does not exceed 5 cubicfeet gross volume, exclusive of casing and insulation; and does notexceed 100 psi maximum allowable working pressure.

Portable Boiler: An internally fired boiler intended for temporary location.

Power Boiler: A boiler in which steam or vapor is generated at a pressuremore than 15 psi.

Reheater: A device that reheats steam to the original superheatedtemperature.

Safety Relief Valve: An automatic pressure relieving device actuated by thestatic pressure upstream of the valve. It opens further with the increasein pressure over the opening pressure. It is used in hot water heatingboilers.

Safety Valve: An automatic pressure relieving device actuated by the staticpressure upstream of the valve. It is used in steam boilers.

Staybolts: Devices used to add to the strength of a boiler by bracing to allowfor increased operating pressures.

Stayed Surfaces: Plates bolted together by staybolts.

Superheater: A device that heats steam so that its temperature rises abovethe boiling point of water for the pressure at which the boiler operates.

Unfired Pressure Vessel: Vessels which are subjected to internal pressure orvacuum that do not have the direct fire of burning fuel impinging onthem. Examples of unfired pressure vessels are compressed air andother gas tanks, steam-jacketed kettles, digesters, vulcanizers, etc.

Wasted Areas: Area of a boiler part that has thinned out from wear.

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NEW YORK STATE DEPARTMENT OF LABOR

BBOOIILLEERR SSAAFFEETTYY BBUURREEAAUU

Boiler Safety Bureau Telephone: (518) 457-2722Harriman State Office Campus FAX: (518) 485-9077Building 12, Room 165Albany, NY 12240

Counties of Jurisdiction: Albany, Clinton, Columbia, Dutchess, Essex, Greene, Rensselaer, Saratoga, Schenectady, Schoharie, Ulster, Warren, and Washington

Boiler Safety Bureau Telephone: (516) 485-4406175 Fulton Avenue FAX: (516) 485-0155Room 309Hempstead, NY 11550

Counties of Jurisdiction: Nassau and Suffolk

Boiler Safety Bureau Telephone: (914) 997-9572120 Bloomingdale Road FAX: (914) 997-9528White Plains, NY 10605

Counties of Jurisdiction: Orange, Putnam, Rockland, and Westchester

Boiler Safety Bureau Telephone: (315) 793-2657207 Genesee Street FAX: (315) 793-2446Room 701Utica, NY 13501

Counties of Jurisdiction: Chenango, Delaware, Franklin, Fulton,Hamilton, Herkimer, Lewis, Madison, Montgomery, Oneida, Otsego, St.Lawrence, and Sullivan

Boiler Safety Bureau Telephone: (716) 258-4575109 South Union Street, Rm. 402 FAX: (716) 258-4593Rochester, NY 14607

Counties of Jurisdiction: Cattaraugus, Chautauqua, Erie, Genesee, Livingston, Monroe, Niagara, Ontario, Orleans, Wayne, Wyoming, and Yates

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Boiler Safety Bureau Telephone: (315) 479-3296450 S. Salina Street FAX: (315) 479-3451Room 401Syracuse, NY 13202

Counties of Jurisdiction: Allegany, Broome, Cayuga, Chemung, Cortland, Jefferson, Onondaga, Oswego, Schuyler, Seneca, Steuben, Tioga, andTompkins

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NEW YORK STATE DEPARTMENT OF LABOR

Division of Safety and Health

Harriman State Office Building Campus

Building 12 - Room 522Albany, New York 12240

(518) 457-3518

PUBLIC EMPLOYEE SAFETY AND HEALTH (PESH) DISTRICT OFFICES

Harriman State Office Bldg. CampusBuilding 12 - Room 158Albany, NY 12240(518) 457-5508

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450 South Salina StreetSyracuse, NY 13202(315) 479-3212

175 Fulton AvenueHempstead, NY 11550(516) 485-4408

44 Hawley Street9th FloorBinghamton, NY 13901(607) 721-8211

207 Genesee StreetRoom 703AUtica, NY 13501(315) 793-2258

345 Hudson StreetRoom 7023New York, NY 10014(212) 352-6087

65 Court StreetRoom 400Buffalo, NY 14202(716) 847-7134

120 Bloomingdale RoadWhite Plains, NY 10605(914) 997-9510

109 South Union Street, Room 402Rochester, NY 14607(716) 258-4570

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(FOR PRIVATE SECTOR EMPLOYEES)

NEW YORK REGIONAL OFFICE

201 Varick Street - Room 670New York, New York 10014

(212) 337-2378

REGIONAL OFFICE AREAS

Albany Area Office County Coverage

401 New Karner Road Albany, Clinton, Columbia, Dutchess, Essex,Suite 300 Fulton, Greene, Hamilton, Montgomery, Albany, NY 12205-3809 Orange, Putnam, Rensselaer, Saratoga,(518) 464-4338 Schenectady, Schoharie, Sullivan, Ulster,

Warren, and Washington

Bayside Area Office County Coverage

42-40 Bell Boulevard QueensBayside, NY 11361(718) 279-9060

Buffalo Area Office County Coverage

5360 Genesee Street Allegany, Cattaraugus, Chautauqua, Erie,Bowmansville, NY 14026 Genesee, Livingston, Monroe, Niagara,(716) 684-3891 Orleans, and Wyoming

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Long Island Area Office County Coverage

1400 Old Country Road Nassau and SuffolkSuite 208Westbury, NY 11590(516) 334-3344

Manhattan Area Office County Coverage

World Trade Center Kings and New YorkBuilding 6 - Room 881New York, NY 10048(212) 466-2482

Syracuse Area Office County Coverage

3300 Vickery Road Broome, Cayuga, Chemung, Chenango,North Syracuse, NY 13212 Cortland, Delaware, Franklin, Herkimer,(315) 451-0808 Jefferson, Lewis, Madison, Oneida, Onondaga,

Ontario, Oswego, Otsego, Schuyler, Seneca, St. Lawrence, Steuben, Tioga, Tompkins,Wayne, and Yates

Tarrytown Area Office County Coverage

660 White Plains Road Bronx, Rockland, and Westchester4th Floor - Suite 480Tarrytown, NY 10591(914) 524-7510