22 | Plant & Works Engineering www.pwemag.co.uk June/July 2024 Process, Controls & Plant Focus on: Boilers, Burners & Controls education, training, and experience. Operators must be capable of recognising the limits of their expertise and seeking assistance when necessary and their duties are determined by site-specific risk assessments. Employers have general duties to provide safe workplaces and adequate staff training under the Health & Safety at Work Act 1974, MHSWR, and PUWER. These responsibilities cannot be delegated to employees or third parties. Qualified electricians or electrical engineers must manage electrical issues associated with boilers, ensuring electrical safety, compliance with regulations, and implementing safety measures. Individuals monitoring boiler alarms must be adequately trained to respond appropriately to alarm conditions, ensuring safety before seeking assistance. Access during emergencies should be restricted to trained personnel. Maintenance personnel require sufficient knowledge and training to carry out their duties safely, performing tasks only for which they are trained and competent. User/owners hiring subcontractors for specialised tasks must ensure their competency, oversee their work, and ensure compliance with legal requirements and safety standards. Manning and supervision levels are determined by detailed risk assessments, considering factors like automation, location, water quality, and operational scenarios. Electric boilers require a competent operator present during start-up and lockout. Advanced automation may still necessitate full-time supervision for steam security or other reasons. Maintenance, repair & modification Boiler systems must be properly maintained to prevent danger, adhering to PSSR Regulation 12 and PUWER Regulation 5. Responsibility for maintenance should be clearly defined, with the user/owner ensuring all personnel are competent, boiler operators handing over safely, and maintenance checked before the boiler is back in operation. Steam leaks should be promptly repaired, and maintenance activities should be documented, including maintenance frequency, and logs kept up to date. Before any modifications or repairs, a risk assessment must be conducted and the CP should assess the effects on pressure equipment, reviewing the WSE as required. Significant repairs must address causal factors and comply with PSSR Regulation 13, documenting alterations and ensuring equivalent standards. Operator training Employers must ensure all personnel possess adequate knowledge of boiler systems and receive training under PUWER Reg 9. Training should be ongoing, structured, and updated to reflect technological advancements and legislative changes, and should cover boiler operation, controls, emergency procedures, legal aspects, and site-specific elements. Competence levels and training requirements must be reviewed, especially with system modifications, and employers must maintain training and assessment records securely for audit purposes. Personnel, including managers and operators, must undergo regular work audits and periodic reassessment of training. Training validation must include written and/or oral assessments with recorded results. Essential elements of boiler house training should include understanding Steam Boiler Water Treatment (SBWT) principles to maintain water quality. Recommended courses include CertIBO for operators, DipBOM for managers, and SBWT training as part of the CEA suite. Periodic inspection A boiler must be examined according to a WSE that details parts, examination types, and intervals, and may be written and certified by an independent or in-house CP. The examination includes two phases: “out of service” and “in service.”, with the latter involving verifying protective devices such as pressure gauge, controller, safety relief valve, and water level controls. Post-examination, the CP should issue a report with recommendations, while other devices such as control system power failure and critical alarms should also be checked and tested. Energy & the environment Efficient boiler energy management is crucial for cost reduction, safety, and plant longevity, so seeking expert advice before altering operating parameters ensures safety, environmental compliance, and efficiency. Options such as metering for efficiency monitoring, water treatment, energy improvement devices (e.g., variable speed drives), and plant scheduling for optimisation should all be considered. It is worth noting that simply reducing steam pressure may not always enhance efficiency, so measurement is therefore recommended to demonstrate efficiency. Electric boilers are not subject to emissions regulations, but environmental considerations such as noise and waste streams require attention. Water discharged must meet utility restrictions, and resources on legislation and guidance are available from government and industry websites. Large organisations may need to comply with the Energy Saving Opportunities Scheme (ESOS). Conclusion The CEA’s BG13 stands as a comprehensive guide for the management of electric steam boilers, addressing design, installation, operation, and maintenance best practices. It serves as a vital resource for professionals involved in boiler systems, covering essential aspects such as safety and compliance with legal standards. By adhering to BG13 guidelines, organisations can ensure the safe and efficient operation of boiler systems, mitigating risks and maximising longevity. Furthermore, considerations for energy management and environmental impact underscore the document’s relevance in promoting sustainable practices within industrial settings. Overall, BG13 provides a comprehensive framework for ensuring the optimal performance and safety of electric steam boilers, contributing to the overall efficiency and sustainability of industrial operations. For further information please visit www.fulton.co.uk
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