Process, Controls & Plant Focus on: Boilers, Burners & Controls 20 | Plant & Works Engineering www.pwemag.co.uk June/July 2024 Fulton managing director Carl Knight delves into the importance of BG13 and the insights it provides into how to ensure the safe operation of electric powered steam boilers. Ensuring best practice & safe operations: The importance of BG13 Guidance for the Safe Operation of Electrically Powered Steam Boilers (Ref: BG13) is a guidance document intended to assist the managers, designers, operators, maintenance personnel and Competent Persons (CP) of new and existing steam boiler systems. Developed and written by the Combustion Engineering Association (CEA) and in consultation with other stakeholders – like Fulton – within the steam boiler industry. It serves as a vital resource to those named and addresses key issues including design, installation, safe operation, maintenance requirements, and compliance with legal standards. The document covers various dangers and challenges including loss of feed water, overpressure, overheating, electrical safety, and water treatment. Electric boilers – classified as small, medium, or large – encompass two main types: electric boilers and electrode boilers. Electric boilers utilise fully immersed heating elements, while electrode boilers employ conducting probes or electrodes to directly heat the water. BG13 applies to industrial and commercial electrically powered steam boiler plants with a working pressure up to 32 bar gauge. It excludes steam boilers exceeding 37 MW nett rated thermal input or above 32 bar gauge working pressure, as well as coffee boilers, jet type electrode boilers, and hot water boilers. Nevertheless, the principles outlined in BG13 can still be applied where suitable and applicable, even to excluded boiler types. Design & installation Proper design and installation are fundamental to the safe operation of electric steam boilers. BG13 outlines design considerations such as sizing the boiler to meet the specific requirements of the application, ensuring adequate ventilation, and implementing appropriate safety features such as pressure relief valves and automatic shutdown systems. To guarantee compliance with BG13 standards, installation should be undertaken by qualified professionals and follow manufacturer guidelines and relevant regulations. Boiler operation This section outlines operational requirements and routine checks for electric boiler systems. Employers must conduct site-specific risk assessments to determine appropriate controls, supervision levels, and maintenance. Before use, boilers must be examined by a competent person and subsequently tested according to a Written Scheme of Examination (WSE). Boiler instructions should cover safe operation, daily checks, start-up procedures, safe work practices, and notification of significant operational changes. System re-starts following lock-out require a suitably experienced operator to avoid potential risks. Routine testing of controls, limiters, and water quality is crucial for safe and efficient operation. Testing frequency should be based on risk assessment, manufacturer’s instructions, and operational requirements. Records of tests and maintenance activities must be maintained for audit purposes. Water level controls need specific testing, with results logged and corrective actions taken as necessary. Feed water and boiler water checks, including chemical dosing and quality assessments, should be conducted regularly. Special consideration must be given to water treatment for standby and unused boilers to prevent scale build-up and ensure system integrity. Personnel & responsibilities The user/owner must appoint competent individuals responsible for daily boiler operation, with competence entailing relevant Fulton managing director Carl Knight
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