BOILER - TECHNICIANS ROLES IN BOILER (STARTUP, SHUTDOWN, EMERGENCY, LOCKOUT AND TAKEOUT)

BOILER - TECHNICIANS ROLES IN BOILER (STARTUP, SHUTDOWN, EMERGENCY, LOCKOUT AND TAKEOUT)

• Technicians must be familiar with boiler procedures, including startup, shutdown, lockout/tagout, and emergency procedures. The procedures that follow are generic in nature. 

• Technicians should always refer to site-specific procedures before performing any work on their unit.

STARTUP:
1. Inform control room personnel that the boiler is going to be put into service.
2. Use the peepholes to inspect the inside of the boiler and verify that it is free of debris
(e.g., scaffold boards, rain suits, and tools) and that the refractory lining, tubes, and tube supports are all intact.
3. Inspect the outside of the boiler for loose flanges around inlet and outlet piping. Ensure that all blinds have been removed, valves are in their proper startup positions, and the pressure relief valve is properly lined up.
4. Inspect the condition of the draft fan, the damper, and the fuel gas system to ensure all are in satisfactory operating condition.
5. While in close communication with control room personnel, open the damper and start up the draft fan per standard operating procedures.
6. Fill the boiler to its normal water level to satisfy the interlock (control safety systems
that have to be verified before boiler startup) for proper water level.
7. After the draft in the boiler is stable and has been purged for the required length of time, open the fuel gas supply to the burner and the pilot gas block valves.
8. Inform control room personnel that the pilot is being ignited.
9. After all of the pilots are lit and burning (confirmed through visual observation), open the primary and secondary air registers as required. Slowly open the main burner block valves one at a time until all burners are burning.
10. Remain in the boiler area to inspect the flames for proper flame patterns and general operation (e.g., draft fan and fuel supply).
11. Use the peepholes to inspect the inside of the boiler and look for uniform color of the tubes.
Note: Many of these steps are included in a boiler automated control system.

SHUTDOWN:
With some exceptions, boiler shutdown is the reverse of the startup procedure.
1. Gradually reduce load and firing rate.
2. Turn off fuel.
3. Shut steam header valve.
4. Shut down feedwater pump.
5. Open vents and drains.
6. Leave fans on to help cool boiler.
The control room operator should monitor conditions and inform the outside operator when it is safe to block in all the burners, shut down the fan, and close the damper.

EMERGENCY:
In an emergency, one fuel gas block valve (often referred to as the fireman) usually is
designated as the main shutoff valve. Generally, the draft fan continues to run and the damper remains open. The only thing the outside operator does is block in the burners, block in the fuel, and stop all pumps.

Lockout / TAGOUT FOR MAINTENANCE:
Each company has its own lockout/tagout procedures. Process technicians must be familiar with these procedures before performing any maintenance.