CSEA / Local 1000 AFSCME / AFL-CIO

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
Boile r
Sa fe ty
for Low Pre ssure a nd
Hig h Pre ssure Boile rs
Produced through a grant from the New York State Department of Labor
Safety and Health Training and Education Program, Grant #8506
2000 CSEA, Inc.
The information in this booklet has been compiled from
sources believed to be reliable and represents the best
current opinion on the subject. No warranty, guarantee, or
representation is made by the Civil Service Employees
Association, Inc. as to its absolute correctness or sufficiency
of any representation in this (and other publications), or that
other or additional measures may not be required under
particular or exceptional conditions or circumstances.
T Ta a b b l l e e o o f f C C o o n n t t e e n n t t s s
Page
Int roduc t ion ............................................................................................................1
Boile r Safe t y ............................................................................................................2
Low Pre s s ure Boile rs (ICR # 4 )..................................................................................8
Boiler Inspections........................................................................................8
Prohibited Installations ..............................................................................9
Condemned Boilers and Components ........................................................11
Stamping of Low Pressure Boilers..............................................................11
Specific Requirements for Low Pressure Boilers ........................................11
Installations, Repairs, and Replacements for Low Pressure Boilers ............16
Heat Generating Apparatus - General Provisions ......................................19
Heat Generating Apparatus - Special Provisions ........................................21
Flame Safeguard Controls for Gas Fired Boilers ........................................24
General Requirements for Oil Burners ......................................................24
High Pre s s ure Boile rs (ICR # 1 4 ) ............................................................................27
Boiler Inspections......................................................................................27
Repairs, Alterations and Miscellaneous Requirements ..............................32
Riveted Repairs ........................................................................................32
Re-rating and De-rating a Boiler................................................................34
Reinstallation of a Boiler ..........................................................................34
Heating of Liquids ....................................................................................35
Removal of Waste Gases from Boilers ........................................................35
Power Boiler: New Installations ................................................................35
Water Level Indicators ..............................................................................37
Hydrostatic Tests ......................................................................................40
Stamping of High Pressure Boilers ............................................................40
Power Boilers: Existing Installations ........................................................40
Safety Valves for Power Boilers ..................................................................40
Fittings and Appliances ............................................................................41
Miniature Boilers ......................................................................................42
Boile r Che mic al Hazards ........................................................................................44
Glos s ary ................................................................................................................46
NYS De pt . of Labor Boile r Safe t y Bure au Offic e s ..................................................48
NYS De pt . of Labor PESH Bure au Offic e s ..............................................................49
Fe de ral OSHA Offic e s ............................................................................................51
1
B O I L E R S A F E T Y
I I N N T TR RO O D D U UC C T TI I O O N N
Boilers can provide efficient and long-term heating applications for small
areas and for huge building complexes. Boilers are available in various
sizes and are designed for the buildings that they must heat.
Modern boiler technology has made boilers not only more efficient, but
safer as well. However, boilers are usually operated under high
temperatures and pressures which, if not properly controlled, can cause
explosions with devastating affects.
A number of years ago in a telephone company building in New York
City, a boiler explosion occurred in the basement. Safety devices did not
operate properly and the boiler blew. The resulting explosion tore through
a 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 employer
must 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 and
maintenance procedures.
2
B BO O I I L LE ER R S SA A F FE ET TY Y
Boile r Room Hazards
Following is a list of some of the hazards that can occur in a boiler room:
G Safety or safety relief valves that do not operate properly can cause a build-
up of boiler pressure.
G Becoming asphyxiated or injured while cleaning boilers because proper
procedures were not followed.
G Slippery floors due to inadequate clean-up of oil and grease spills.
G Improper storage of boiler chemicals.
G Asbestos insulation flaking off pipes and breeching.
G Working platforms and ladders not provided or in poor repair.
G Energy controlling devices such as switches, valves, etc. not being properly
locked and/or tagged out before working on equipment controlled by them.
G Leakage at gas and fuel supply lines.
G Flame failure, fuel cut-off, and other controls not working properly.
G Insufficient areas of clearance around boilers.
G Improper welding operations and repairs.
G Improperly placed exits that prevent egress of workers in the event of a
steam leak or explosion.
G Unguarded pump shafts and unguarded nip points where belt and pulleys
are in operation such as on air compressors.
These are just a few unsafe conditions that may be present. It is
important that your employer maintain a safe worksite.
3
Laws that Protect Boi l er Operators and
Empl oyees and Occupants i n Bui l di ngs
Housi ng Boi l ers
If your employer has a low pressure boiler installation, the New York
State Department of Labor Industrial Code Rule #4 (ICR #4) must be
followed. Low pressure boilers are steam boilers operating at 15 pounds
per square inch (15 psi) or less and hot water boilers operating at pressures
not exceeding 160 psi.
If your employer has a high pressure boiler installation, the New York
State Department of Labor Industrial Code Rule #14 (ICR#14) must be
followed. 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 Labor
Boiler Safety Bureau. There are activities in a boiler room that may not be
covered by these rules but will be covered by OSHA standards that are
enforced by the New York State Department of Labor Public Employees
Safety and Health (PESH) Bureau or by Federal OSHA for private sector
employees. These standards describe the requirements for engineering and
work practice controls to reduce potential exposure to chemicals to below
the permissible exposure limits (PEL), how welding must be safely
conducted, 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 the
necessary safeguards.
Ge ne ral
Fl oors
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.
4
Li ghti ng
Boiler rooms should have adequate illumination. It is recommended
that 100 foot-candles of illumination be provided. An inexpensive light
meter can be used to determine light levels. It is important that dials,
gauges, and controls be well illuminated. This is important so that
potentially 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 New
York State Uniform Fire Prevention and Building Code has requirements
for emergency lighting.
Boi l er Room Encl osures
The boiler room, if part of an occupied building, must be enclosed in fire
resistive construction. The door(s) to the room, as well as door frames,
must also be fire resistive. Both OSHA and the New York State Uniform
Fire 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.
Emergenci es
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.
Boi l ers as Confi ned Spaces
Boilers are considered confined spaces. When employees enter them to
clean, repair, etc., the OSHA Permit-Required Confined Space Standard
must be followed by the employer. The employer must establish safe entry
5
procedures. This includes an entry permit, attendant, written procedures,
etc. Your employer should consult the OSHA Permit-Required Confined
Space Entry Standard.
If the boiler can be adequately ventilated so that any hazardous
atmosphere is eliminated while workers are in the boiler and no other
hazards exist, the Permit-Required Confined Space Entry Standard does not
have to be followed.
Boi l er Cl eani ng
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 adequate
protective equipment, hard hats, heavy duty work gloves, eye protection,
coveralls, etc. must be worn. This is required under the OSHA Personal
Protective 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.
Noi se Exposure
Boiler room noise can be above 90 decibels (dB) which is above the
OSHA 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.
6
Boi l er Chemical s
Chemicals are used in the boiler room to treat and test boiler water. Some
of 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 by
the 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 Chemical s
Flammable and combustible chemicals stored in small containers should be
s t o red in Underwriters Laboratories (UL) or Factory Mutual (FM) appro v e d
safety cans. It is also recommended these cans be stored in UL or FM
a p p roved flammable storage cabinets. Incompatible chemicals must not be
s 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 of
flammable materials must be grounded to a grounded building structure such
as 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 flammable
l i q u i d .
Both OSHA and the New York State Uniform Fire Prevention and Building
Code limit the amount of flammable and combustible material that can be
safely 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 Tool s and Equi pment
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 double
block-n-bleed is in use, there must not be any explosive atmospheres. No work
should be done in explosive atmospheres without the workers being specially
t r a i n e d .
7
Lock-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 the
OSHA Lock-Out/Tag-Out Standard. This standard protects against injury
by 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 be
drained 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 regulates
the abatement of asbestos, whether done by in-house employees or by an
outside contractor. This code rule must be consulted before any abatement
is carried out.
Industrial Code Rule #56 requires that workers removing asbestos, even
in small pipes or when doing boiler repair, must have a current New York
State Asbestos Handlers Certificate and the workers employer must have
a current New York State Department of Labor Asbestos Contractors
License.
8
L LO O W W P PR RE ES SS SU UR RE E B BO O I I L LE ER RS S
- - I I N N D D U US ST TR RI I A A L L C C O O D D E E R RU UL LE E # # 4 4 ( ( I I C C R R # # 4 4 ) )
Boi ler 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 inspected
and insured by an authorized insurance company.
If a dangerous condition is noted, the Department of Labor will shut down
the boiler until the condition is corre c t e d .
Cast i ron boi l ers must be inspected externally at least annually.
Steel boi lers must be inspected externally at least annually.
Low pre s s u re steam boi l ers must be inspected internally at least every
t h ree years. Hot water boi l ers must be inspected internally once every
five years.
Cert ifi cat e of Ins pecti on
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 working
p re s s u re or temperature allowable until the next inspection.
P reparing a Boiler for Ins pect i on
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.
9
Employe rs Re s pons ibilit y
The employer must provide a competent person to disassemble,
reassemble, test, adjust, operate or handle any part of the boiler if it is
required during the inspection. This person must be under the supervision
of the inspector. Because a boiler is under high pressure and temperature,
anyone working on a boiler must understand its operation so that they can
properly assist the inspector.
Employe rs Not ic e
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.
Prohi bi ted Instal l ati ons
Ge ne ral
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 boiler
component.
No person can knowingly operate a defective boiler.
No person can knowingly operate a boiler at a pressure or
temperature exceeding the maximum allowable pressure or temperature.
Non-s t andard c ompone nt s
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 as
part 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.
10
Se c ond-hand boile rs
If a used boiler is installed without having been inspected by the
Department of Labor, there could be undetected defects that could cause
the boiler to malfunction. This would create a hazardous condition.
Second-hand boilers cannot be installed in New York State without first
obtaining permission from the Department of Labor. After the boiler is
installed, the Department of Labor or insurance company must inspect it.
If an insurance company conducts the inspection, a copy of the report must
be sent to the Department of Labor.
Boi l er Operator
New York State law does not require a qualified person to be on duty at
all times in the boiler room as long as the boilers are equipped with
automatic shut-down systems. It is recommended a qualified person be on
duty during each shift. Every worker attending a boiler must be trained by
the 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:
G Blow-down of water column, sight glass and other safety equipment.
G Blow-down of mud drum and header.
G Record of water treatment.
G Test of safety valves.
G Record of any operating problems or deficiencies.
G Signature of the boiler operator.
The log must be available for the Department of Labor and insurance
company inspector.
11
Condemned Boi l ers and Components
Ge ne ral
If a boiler inspector finds a boiler or boiler components so defective that
repair cannot be made, the Department of Labor has the authority to
condemn the boiler and have it immediately discontinued from service.
Stampi ng of Low Pressure Boi l ers
Ge ne ral
All low pressure boilers must be built in accordance with American
Society of Mechanical Engineers (ASME) requirements by the manufacturer.
The manufacturer must stamp an H on all boilers meeting ASME
specifications. These specifications ensure that the boiler will operate safely
if proper procedures are followed.
Speci fi c Requi rements
for Low Pressure Boi l ers
Safe t y valve s for low pre s s ure s t e am boile rs
Safety valves are extremely important devices because they prevent
pressure from building up in the boiler that could cause the boiler to
explode.
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 inch
gauge (5 psig) above the maximum allowable working pressure with all
valves open. This is with the steam generating equipment operating at
maximum.
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.
12
No safety valve can be smaller than 3/4 inch nor larger than 4 1/2
inches.
Some boilers, because of their increased capacity, will require two or
more 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.
Re lie f valve s for low pre s s ure hot wat e r boile rs
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 when
operating conditions change or additional boiler heating surfaces are
installed.
Relief valves must be of the spring-loaded type without disk guides on
the 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 pressures
not 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 from
its seat at least 1/16 inch when there is no pressure on the boiler.
13
Ins t allat ion and re plac e me nt of s afe t y
and re lie f valve s for low pre s s ure boile rs
Valves must be in proper working order before the boiler is put in
service.
No person is permitted to load or tamper with valves to maintain a
pressure or temperature in excess of the maximum allowable pressure or
temperature 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.
Dis c harge pipe s for s afe t y and re lie f valve s
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.
Gauge s
Gauges are necessary on boilers so the attendants can make sure that
the 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 gauge
must 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.
14
Ins t allat ion and re plac e me nt of s t e am gauge s for low pre s s ure boile rs
Replacement must be in the same location as the factory installed gauge.
Wat e r gauge s
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 attached
to the water column or boiler by means of valved fittings. The lower fitting
must be fitted with a drain. The gauge must be accessible without the use
of tools and must be visible.
St op valve s and c he c k valve s
Stop and check valves control the flow of water or steam between the
boiler and the heat distribution piping. This enables the boiler to be
isolated 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.
Fe e dwat e r c onne c t ions
Feedwater connections must be separate from any other connections.
Feedwater connections for cast iron steam boilers, when connected from a
pressure line, must be made to the condensate return line or the
condensate return pump reservoir. Feedwater connections cannot be made
directly to the boiler.
A check valve must be in the feedwater line at the boiler for all boilers.
15
Conde ns at e le ve l c ont rol
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.
The rmome t e rs
Each hot water boiler must have a thermometer located and connected
where it can be easily read. The thermometer tells the attendant what the
water temperature is. Excessively high temperatures could be dangerous to
boiler operation.
Combus t ion re gulat ors
Each automatically fired hot water boiler must be provided with a
temperature-activated control at or near the boiler outlet which controls
the rate of combustion to prevent the temperature of the water from rising
above 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 set
to permit operation of the boiler if the temperature of the water is above
250 F.
Bot t om 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 wat e r c ut offs
A low water cutoff is a device that protects the boiler by stopping its
operation if the water level goes below the safe point.
16
Each automatically fired steamor 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 c ont rols
All hot water boilers installed after March 31, 1965 and boilers installed
before that date which have new burners and controls, must have a
high limit temperature-actuated control. It must automatically stop the
boiler if the temperature of the boiler water at the boiler outlet rises to
30 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 limit
pressure-actuated control. It must automatically stop the boiler if steam
pressure 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.
Instal l ati ons, Repai rs and Repl acements
of Low Pressure Boi l ers
Ge ne ral
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.
Cle aranc e around boile rs ins t alle d be fore Marc h 3 1 , 1 9 6 5
Adequate clearance around boilers enables workers to safely make
repairs and conduct inspections. If there is insufficient clearance, parts
cannot be inspected or repaired and workers could injure themselves.
17
Sufficient clearance must be provided around any boiler so that proper
operation, maintenance and inspection can be done.
Cle aranc e around boile rs ins t alle d aft e r Marc h 3 1 , 1 9 6 5
in a s pac e not pre vious ly us e d t o hous e a boile r
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 than
four 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 than
six 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 overhead
structures.
Cle aranc e around boile rs ins t alle d aft e r Marc h 3 1 , 1 9 6 5
in a s pac e or room t hat pre vious ly hous e d a boile r
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 plat forms and ladde rs for boile rs ins t alle d
aft e r Marc h 3 1 , 1 9 6 5
Platforms, ladders, and stairs must enable attendants to safely inspect
and work on boilers. The worker must be protected from falling and must
have adequate working surfaces.
18
Working platforms must not be less than 24 inches wide and must be
made 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 must
have a railing not less than 42 inches high with a midrail. The railing must
be 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 the
valve.
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 above
the floor or nearest walkway, a working platform must be installed to
provide 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, a
working platform must be installed to provide access. A permanent ladder
or stair need not be provided.
Ac c e s s for ins pe c t ion for wat e r t ube boile rs
ins t alle d aft e r Marc h 3 1 , 1 9 6 5
A water tube boiler must be installed so that all drum heads (area where
water circulates) are accessible for external inspection.
19
Boi l er room exi ts for boi l ers i nstal l ed after March 31, 1965
Boile rs ins t alle d in e xis t ing s pac e s or rooms
whic h pre vious ly hous e d a boile r
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.
Boile rs ins t alle d in ne w s pac e s 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 be
provided. One of the exits must be at least 36 inches wide. If a door is
provided it must open in the direction of egress. The other exit may be a
permanent vertical or inclined metal ladder not less than 18 inches wide
which accesses an opening not less than 36 inches wide. If the opening is
provided with a door, it must open in the direction of egress.
Boile r room e xit s for boile rs ins t alle d be fore Marc h 3 1 , 1 9 6 5
The space must be provided with at least one exit not less than 30
inches wide. If a door is provided, it must open in the direction of egress.
Heat Generati ng Apparatus -
General Provi si ons
Note: This section applies to all boilers
regardless of date of installation.
Ins t allat ion
Installation must be made to provide reasonable accessibility for
cleaning 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 observe
burner operations.
20
Air s upply for c ombus t ion
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 must
be 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 not
contain a boiler explosion. This would endanger the building occupants.
By being on the outside wall, the force of the explosion would be to the
outside away from the building. This is also required by the New York State
Uniform Fire Prevention and Building Code.
Maint e nanc e
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.
Ele c t ric al e quipme nt and wiring
Installation of electrical equipment must be neat and orderly. Wiring
must be properly supported and protected. All wiring and equipment must
be installed in compliance with OSHA standards and the National Electric
Code (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 of
the hole the wires pass through. This is required to prevent abrasion of the
wires.
21
Detachable plug connectors cannot be used in circuits where
disconnection 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 a
manner that they can be connected and reconnected without breaking a
soldered connection or breaking or cutting wires.
Heat Generati ng Apparatus -
Speci al Provi si ons
Note: The provisions of this section apply to boilers
installed after March 31, 1965.
Cont rol c irc uit s
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 of
the circuit. Safety controls or protective devices must cut off power to
hot (ungrounded) conductors. Safety controls must go to the off position
without 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.
He at ge ne rat ing apparat us fire d wit h pulve rize d c ont rols
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.
22
Mechanical and electrical interlocks must be provided on induced (1)
draft fans, (2) forced draft fans, (3) primary oil blowers, (4) coal
pulverizers 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 motor
and 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 burne rs
All controls must be accessible for normal servicing and adjustment
and 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 ins t allat ion
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.
23
Gas valve s
Lubricants used on gas valves must be resistant to liquified petroleum
gas.
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 s upply line s
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 to
liquified petroleum gases.
Connections for pilot gas supply lines must be located so that the tubing
and 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).
24
Fl ame Safeguard Control s
for Gas-Fi red Boi l ers
Note: The provisions of this section apply to all gas-fired boilers
without regard to date of installation.
Flame guard de vic e s
All gas-fired boilers must be equipped with adequate flame safeguard
devices.
Pilot or t orc h re liabilit y
On manually lighted or automatically ignited gas-fired boilers, the
pilot or torch must be at the proper location to ignite the main burner
before an electrical circuit opens the main burner gas valve.
Burne r flame failure c ont rols
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 Requi rements for Oi l Bur ners
Note: The provisions of this section apply to all oil burners
regardless of date of installation.
Cont rols
All controls must be available for servicing and adjustment in position
and must be replaceable during normal servicing.
25
Safe t y c ont rols for abnormal oil dis c harge
Burners must be equipped with automatic primary safety controls to
prevent abnormal discharge of oil at the burner in case of ignition or flame
failure.
Sharp e dge s
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.
Loc king adjus t able part s
Adjustable and moving parts must be locked to prevent shifting.
St raine rs
Small orifices in oil supply systems likely to become clogged must be
protected by a suitable strainer.
Fit t ings and piping
Tubing must be protected from damage. When pipe are disconnected,
dripping oil must be kept away from moving parts.
Bre akable gauge s
A glass gauge or sight feed cannot be used if its breakage could
release fuel oil from the system.
26
Fl ame Safeguard Control Requi rements for Al l
Oi l Burners Instal l ed Before March 31, 1965
Pilot light re liabilit y
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 must
open only after the pilot light comes on so that the oil will be ignited. If the
pilot 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.
Fl ame Safeguard Control Requi rements for Al l
Oi l Bur ners Instal l ed After March 31, 1965
Pilot light s
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 on
so that unburned fuel which could cause a fire or explosion does not
accumulate.
27
H H I I G G H H P PR RE ES SS SU UR RE E B BO O I I L LE ER RS S - -
I I N N D D U US ST TR RI I A A L L C C O O D D E E R RU UL LE E # # 1 1 4 4 ( ( I I C C R R # # 1 1 4 4 ) )
Boi l er I nspecti ons
Ge ne ral
High pressure boilers operate at higher pressures and temperatures
than low pressure boilers. The requirements for inspection of high pressure
boilers are more strict than for low pressure boilers.
High pressure steam boilers must be inspected internally and externally
at 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 least
every three years. If equipped with manholes and handholes, an annual
internal inspection is required. An external inspection must be made once
a year approximately six months after each internal inspection.
Ins pe c t ion pre parat ion
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.
Ins uranc e ins pe c t ions
If boiler inspections are made by an authorized insurance company,
inspections do not have to be made by the New York State Department of
Labor.
Ce rt ific at e of ins pe c t ion
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
28
certificate for portable boilers must be on the premises where the boiler
is being operated and must be available at all times.
No boiler can be operated at a pressure in excess of the allowable
working pressure specified on the latest Certificate of Inspection.
If steam pressure has to be increased above the allowable working
pressure specified in the Certificate of Inspection, the Department of Labor
must be notified and a new certificate is required.
Safe t y applianc e s
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.
Numbe rs on boile rs
No one is permitted to deface any number on a boiler or a Certificate of
Inspection. Only an inspector can change numbers or certificates.
De fe c t ive boile rs
A boiler with any defect that affects its safety must be taken out of service
and the Department of Labor and insurance company must be notified.
Conde mne d boile rs
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.
Canc e llat ion of Ce rt ific at e
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.
29
Plat forms , ladde rs , and e xit s
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 inches
wide. They also must have a 4-inch toeboard and a 42-inch high railing
with 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 when
the openings are over four feet above the floor.
Wherever an employee can be trapped, two means of escape remote from
each other must be provided.
Blow-off t anks
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.
Boile r ope rat or
Persons attending a boiler must have sufficient training so they can
operate the boiler in a safe and efficient manner.
30
The boiler operator must keep a log for each shift. The log must contain
the following information:
G Blow-down of water column, sight glass and other safety equipment.
G Blow-down of mud drum and boilers. The mud drum is the bottom of
the header area where the water circulates.
G Record of water treatment.
G Test of safety valves.
G Record of any operating problems or deficiencies.
G Signature of boiler operator.
The log must be available for inspection by the State boiler inspector and
insurance inspector.
Me c hanic al fue l and fe e d
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 is
not enough water in the boiler and it continues to operate, it could cause
an overpressure. If safety devices do not work, there could be an
explosion.
Electric switches must be able to withstand atmospheric deterioration
and must be approved by the Underwriters Laboratories (UL). They must
be accessible for inspection, cleaning, and repairing.
Maximum allowable working pre s s ure
The maximum allowable working pressure of a power boiler must be
determined in accordance with the American Society of Mechanical
Engineers (ASME) Code.
Pre s s ure c ont rols
Each automatically fired steam power boiler must have at least one
steam pressure control device that shuts off the fuel supply to each boiler
when the steam pressure reaches a preset maximum operating pressure.
31
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.
Ac c ide nt not ific at ion
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 the
appropriate district office of the Department of Labor Public Employee
Safety and Health (PESH) Bureau by the employer. Injuries, illnesses and
deaths must be recorded on the annual DOSH 900 log by the employer.
Boile r c le aranc e s
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 or
partitions for care and inspection.
A clearance of 7 feet must be maintained from the working platform to
the underside of any overhead structure where it is necessary to go on top
of the boiler for maintenance purposes. The clearance must be at least 3
feet and there must be a clearance of at least 6 inches from the highest
point of any valve to the underside of any overhead structure when the
boiler is installed in an existing building.
Pre paring boile rs for hydros t at ic t e s t ing
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.
32
Repai rs, Al terati ons, and
Mi scel l aneous Requi rements
Re pairs and Alt e rat ions
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.
Mat e rials
Materials used in making welding repairs or alterations must conform to
the ASME Code.
Ge ne ral rule s for re pairs
Repairs to boilers must only be performed by an organization that
possesses 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-pressure
parts to pressure parts, weld build-up of worn areas, replacement of boiler
tubes, 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.
Ge ne ral rule s of alt e rat ions
Alterations include increasing allowable working pressure, additions of
33
new nozzles or openings, increase in heating surface, replacement of a
pressure 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 an
ASME Symbol Stamp listed in the ASME Code. The work involved must be
within the scope of the ASME Code Symbol Stampholders Certificate of
Authorization.
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.
We lde rs
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.
Was t e d are as
Wasted areas (areas where the metal has thinned due to wear)
may be built up by welding providing that the inspector judges that the
strength of the structure will not be impaired. Welding build-up of repair is
not permitted on rivet heads, brace ends, attachments to braces, and on
pitted or corroded areas of unbraced surfaces.
34
R RE E- - R RA A T TI I N N G G A A N N D D D D E E- - R RA A T TI I N N G G A A B BO O I I L LE ER R
Re-rati ng
A boiler is re-rated when its maximum allowable pressure or
temperature is increased or minimum temperature is decreased, requiring
additional testing. Re-rating can only be done if it is established in
accordance with the ASME Code, inspection records verify the boiler is
satisfactory for the new conditions, the re-rating is acceptable to the
inspector, and the boiler is pressure-tested for the new rating.
De-rati ng
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 the
inspector.
R RE EI I N N S ST TA A L LL LA A T TI I O O N N O O F F B BO O I I L LE ER RS S
Ge ne ral
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 a
hydrostatic pressure test applied if required by the inspector. A Certificate
of Inspection will be issued if the boiler is safe.
35
Heati ng of Li qui ds
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 prevent
liquid fuels or other harmful liquids from getting into the boiler.
Removal of Waste Gases From Boi l ers
Me ans of e xhaus t
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 by
exhausting the smoke out through a properly designed chimney.
Powe r Boile rs : Ne w Ins t allat ions
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.
Ac c e s s and ins pe c t ion ope nings
All boilers must be provided with suitable inspection openings for
examination or cleaning.
Safe t y valve s and s afe t y re lie f valve s
Each boiler must have at least one safety valve. If it has more than 500
square 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.
36
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.
Safe t y valve and s afe t y re lie f valve t e s t ing and re pair
Valves on power boilers with a maximum allowable working pressure up
to 400 psi must be manually tested not less than once a month and
pressure-tested once a year. Valves on power boilers with a maximum
allowable working pressure over 400 psi must be pressure-tested once each
year.
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.
Safe t y valve c onne c t ions
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 unnecessary
intervening pipe or fitting.
All safety valve or safety relief valve discharges must be located or
piped 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 are
prohibited.
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 for
protection providing the cover does not interfere with its operation.
37
Safe t y valve c ons t ruc t ion
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.
Supe rhe at e r s afe t y valve s
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.
Re he at e r valve s
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.
Out le t c onne c t ions
Every boiler must have proper outlet connections for the required safety
valve(s).
Water Level Indi cators
Wat e r gauge glas s e s
Water gauge glasses are important on boilers because they show what the
safe water level should be. If water levels go below safe levels, the
boiler 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.
38
The lowest visible part of the water gauge glass must be at least two
inches above the lowest permissible water level.
Shut off valve
Each water glass must be equipped with a top and bottom shutoff valve.
Gauge c oc ks
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 the
visible length of the water glass.
Pre s s ure and t e mpe rat ure gauge s
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 so
located and connected that it is easily readable. The gauge must be
installed so that it indicates the temperature in the boiler at all times.
Ins pe c t ors t e s t gauge c onne c t ion
Each boiler must be provided with a valved connection for the purpose of
testing the accuracy of the boiler steam gauge.
St op valve s (the stop valve controls the flow of steam)
Each steam discharge outlet, except for safety valves or safety relief
valves or reheater inlet or outlet connections, must be fitted with a stop
valve. The stop valve controls the flow of steam.
39
St e am 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.
Supe rhe at e r 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 enables
the 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 must
be tested daily when the boiler is in operation.
Re quire me nt s for drains
Drains must be provided in the boiler system wherever water will collect.
Fe e dwat e r s upply
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 adding
water to the boiler system while under pressure. Feedwater pipe must be
provided with stop and check valves so the supply can be shut off to the
boiler when there is an emergency.
Gravit y fe e d re t urn
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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Hydrostati c 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.
Stampi ng of Hi gh Pressure Boi l ers
St amping
When a boiler is completed, it must have all the required stamps affixed
so they are clearly visible. This shows that the boiler is safe to operate at
the rated maximum allowable working pressure.
Power Boi l ers: Exi sti ng Instal l ati ons
Maximum allowable working pressures
Fac t ors of s afe t y
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 greater
safety margin. Boiler safety factors vary from 5 to 7. If a boiler has a
permissible allowable working pressure of 100 psi (the pressure indicated
on the certificate) and a safety factor of 5, it means the boiler can take
pressures 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 down
the system or get to a safe area.
Safety Val ves for Power Boi l ers
Re quire d s afe t y valve s
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.
Fi tti ngs and Appl i ances
Wat e r glas s e s and gauge c oc ks
Each steam boiler must have at least one water glass.
Each boiler must have three or more gauge cocks, located within the
range of the visible length of the water glass, when the maximum allowable
working pressure exceeds 15 psi, except as noted in the code rule.
St e am gauge s
Each boiler must have a steam gauge connected to the steam space or to
the water column or to the steam connection.
St op 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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Mi ni ature Boi l ers
A miniature boiler by definition cannot exceed the following limits:
G 16 inches inside diameter of shell;
G 5 cubic feet gross volume, exclusive of casing and insulation;
G 20 square feet water heating surface;
G 100 psi maximum allowable working pressure.
Pump or fe e d de vic e
Each miniature boiler must be provided with a pumping device to feed
water to the boiler to insure the water level in the boiler is maintained at
safe levels. It must also be provided with feedwater and blow-off
connections.
Wat e r gauge and wat e r le ve l
Each miniature boiler with a definite water level must be equipped with
a glass water gauge for determining water level.
St e am gauge
Each miniature boiler must be equipped with a steam gauge.
Safe t y valve s
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.
St op valve on s t e am line
Each steam line from a miniature boiler must be provided with a stop
valve located as close to the boiler shell or drum as practicable.
Fue l re gulat ing gove rnor
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.
43
B BO O I I L LE ER R
C C H HE EM M I I C C A A L L
H HA A Z ZA A R RD D S S
CHEMI CAL
HEALTH FI RE or EXPLOSI ON PROTECTI VE
HAZARD HAZARD MEASURES
K E Y:
{
44
CHEMI CAL
HEALTH FI RE or EXPLOSI ON PROTECTI VE
HAZARD HAZARD MEASURES
45
46
G G L LO O S SS SA A R RY Y
Alt e rat ion: Change in a boiler that substantially alters the original design and
that requires consideration of the affect of the change on the original
design.
ASME Code : Boiler and pressure vessel code published by the American
Society of Mechanical Engineers.
Boile r: A closed vessel in which steam is generated, water is heated, steam is
superheated, or any combination thereof, under pressure or vacuum for
use external to itself by the application of heat from combustible fuels,
electricity, or any other source.
Conde mne d: A boiler declared unsafe and having an applied stamping
designating it as condemned.
De fe c t ive Boile r: A boiler not provided with all the required controls and
devices in operating order.
De part me nt of Labor: New York State agency responsible for enforcing
Industrial Code Rules #4 and #14. This is done through the Boiler
Safety Bureau.
Ext e rnal Ins pe c t ion: An inspection made while the boiler is in operation.
High Te mpe rat ure Wat e r Boile r: A boiler completely filled with water
intended for operation at pressures in excess of 160 psi at temperatures
in excess of 250 degrees F.
Hot Wat e r He at ing Boile r: A boiler completely filled with water that furnishes
hot water to be used externally to itself at pressures not exceeding 160
psi at temperatures not exceeding 250 degrees F at or near the boiler
outlet.
Ins pe c t or: A boiler inspector who holds a valid certificate of competency
issued by the Department of Labor Boiler Safety Bureau.
Low Pre s s ure Boile r: A boiler producing steam or vapor at a gauge pressure
of 15 psi or less, or producing hot water at a gauge pressure not
exceeding 160 psi, or at a temperature not exceeding 250 degrees F.
Maximum Allowable Working Pre s s ure : The maximum gauge pressure
permissible at the top of a completed vessel in its operating position for a
designated temperature.
47
Maximum Allowable Working Te mpe rat ure : The maximum temperature at
or near the outlet of a hot water boiler, in degrees F, at which the boiler
may be safely operated.
Miniat ure Boile r: A power boiler or high temperature water boiler that does
not exceed 16 inches inside shell diameter; does not exceed 20 square
feet of heating surface, except for electric boilers; does not exceed 5 cubic
feet gross volume, exclusive of casing and insulation; and does not
exceed 100 psi maximum allowable working pressure.
Port able Boile r: An internally fired boiler intended for temporary location.
Powe r Boile r: A boiler in which steam or vapor is generated at a pressure
more than 15 psi.
Re he at e r: A device that reheats steam to the original superheated
temperature.
Safe t y Re lie f Valve : An automatic pressure relieving device actuated by the
static pressure upstream of the valve. It opens further with the increase
in pressure over the opening pressure. It is used in hot water heating
boilers.
Safe t y Valve : An automatic pressure relieving device actuated by the static
pressure upstream of the valve. It is used in steam boilers.
St aybolt s : Devices used to add to the strength of a boiler by bracing to allow
for increased operating pressures.
St aye d Surfac e s : Plates bolted together by staybolts.
Supe rhe at e r: A device that heats steam so that its temperature rises above
the boiling point of water for the pressure at which the boiler operates.
Unfire d Pre s s ure Ve s s e l: Vessels which are subjected to internal pressure or
vacuum that do not have the direct fire of burning fuel impinging on
them. Examples of unfired pressure vessels are compressed air and
other gas tanks, steam-jacketed kettles, digesters, vulcanizers, etc.
Was t e d Are as : Area of a boiler part that has thinned out from wear.
48
NEW YORK STATE DEPARTMENT OF LABOR
B BO O I I L LE ER R S SA A F FE ET TY Y B BU UR RE EA A U U
Boiler Safety Bureau Telephone: (518) 457-2722
Harriman State Office Campus FAX: (518) 485-9077
Building 12, Room 165
Albany, NY 12240
Counti es of J uri sdi cti on: Albany, Clinton, Columbia, Dutchess, Essex,
Greene, Rensselaer, Saratoga, Schenectady, Schoharie, Ulster, Warren, and
Washington
Boiler Safety Bureau Telephone: (516) 485-4406
175 Fulton Avenue FAX: (516) 485-0155
Room 309
Hempstead, NY 11550
Counti es of J uri sdi cti on: Nassau and Suffolk
Boiler Safety Bureau Telephone: (914) 997-9572
120 Bloomingdale Road FAX: (914) 997-9528
White Plains, NY 10605
Counti es of J uri sdi cti on: Orange, Putnam, Rockland, and Westchester
Boiler Safety Bureau Telephone: (315) 793-2657
207 Genesee Street FAX: (315) 793-2446
Room 701
Utica, NY 13501
Counti es of J uri sdi cti on: Chenango, Delaware, Franklin, Fulton,
Hamilton, Herkimer, Lewis, Madison, Montgomery, Oneida, Otsego, St.
Lawrence, and Sullivan
Boiler Safety Bureau Telephone: (716) 258-4575
109 South Union Street, Rm. 402 FAX: (716) 258-4593
Rochester, NY 14607
Counti es of J uri sdi cti on: Cattaraugus, Chautauqua, Erie, Genesee,
Livingston, Monroe, Niagara, Ontario, Orleans, Wayne, Wyoming, and Yates
49
Boiler Safety Bureau Telephone: (315) 479-3296
450 S. Salina Street FAX: (315) 479-3451
Room 401
Syracuse, NY 13202
Counti es of J uri sdi cti on: Allegany, Broome, Cayuga, Chemung, Cortland,
Jefferson, Onondaga, Oswego, Schuyler, Seneca, Steuben, Tioga, and
Tompkins
P PE ES SH H O O F FF FI I C C E ES S
NEW YORK STATE DEPARTMENT OF LABOR
Divis ion of Safe t y and He alt h
Harriman State Office Building Campus
Building 12 - Room 522
Albany, New York 12240
(518) 457-3518
PUBLIC EMPLOYEE SAFETY AND HEALTH (PESH)
DISTRICT OFFICES
Harriman State Office Bldg. Campus
Building 12 - Room 158
Albany, NY 12240
(518) 457-5508
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450 South Salina Street
Syracuse, NY 13202
(315) 479-3212
175 Fulton Avenue
Hempstead, NY 11550
(516) 485-4408
44 Hawley Street
9th Floor
Binghamton, NY 13901
(607) 721-8211
207 Genesee Street
Room 703A
Utica, NY 13501
(315) 793-2258
345 Hudson Street
Room 7023
New York, NY 10014
(212) 352-6087
65 Court Street
Room 400
Buffalo, NY 14202
(716) 847-7134
120 Bloomingdale Road
White Plains, NY 10605
(914) 997-9510
109 South Union Street, Room 402
Rochester, NY 14607
(716) 258-4570
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U U. . S S. . D D E EP PA A R RT TM M E EN N T T O O F F L LA A B BO O R R
O O C C C C U UP PA AT TI I O O N N A A L L S SA A F FE ET TY Y A A N N D D H H E EA A L LT TH H
A A D D M M I I N N I I S ST TR RA A T TI I O O N N O O F FF FI I C C E ES S
(FOR PRIVATE SECTOR EMPLOYEES)
NEW YORK REGIONAL OFFICE
201 Varick Street - Room 670
New York, New York 10014
(212) 337-2378
REGIONAL OFFICE AREAS
Albany Are a Offic e 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
Bays ide Are a Offic e County Coverage
42-40 Bell Boulevard Queens
Bayside, NY 11361
(718) 279-9060
Buffalo Are a Offic e County Coverage
5360 Genesee Street Allegany, Cattaraugus, Chautauqua, Erie,
Bowmansville, NY 14026 Genesee, Livingston, Monroe, Niagara,
(716) 684-3891 Orleans, and Wyoming
52
Long Is land Are a Offic e County Coverage
1400 Old Country Road Nassau and Suffolk
Suite 208
Westbury, NY 11590
(516) 334-3344
Manhat t an Are a Offic e County Coverage
World Trade Center Kings and New York
Building 6 - Room 881
New York, NY 10048
(212) 466-2482
Syrac us e Are a Offic e 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
Tarryt own Are a Offic e County Coverage
660 White Plains Road Bronx, Rockland, and Westchester
4th Floor - Suite 480
Tarrytown, NY 10591
(914) 524-7510