OPERATING HAZARD CAUSE EFFECT PREVENTION

OIL FIRING
Low fuel temperature (on equipment Faulty and/or fouled heater element. Oil Poor atomization. Dirty or smoky fire. Check oil temperature periodically.
burning fuel oil, which requires heating temperature control setting too low. Discharge of unburned oil in the furnace. Check heaters periodically. Follow
prior to combustion.) Heater electric power off. Steam supply Fireside explosion of puff. Fire. Boiler manufacturer's instructions.
closed. Explosion. damage. Property damage. Loss of life
and/or injury to personnel.
       
High fuel temperature Improper Thermostat setting. Steam Poor atomization. Oil gasification. Check heaters and controls periodically.
control valve stuck open (steam heater). Unstable flame. Fireside explosion or Follow manufacturer's instructions.
Electrical supply contacts welded closed puff. Fire. Boiler damage. Property
(electrical heater). Explosion. damage. Loss of life and/or personnel

       
Low atomizing air or steam pressure Supply line valves inoperative or not Poor atomization. Dirty or smoky fires. Insulate all steam lines. Check proper
fully open. Improper control valve Discharge of unburned oil in furnace. trap operation periodically. Follow
setting. Low supply pressure. Explosion. Fireside explosion or puff. Fire. Boiler manufacturer's instructions.
damage. Property damage. Loss of life
and/or injury to personnel.

       
Wet steam during atomizing. Steam wet from source. Steam line not Poor atomization. Dirty or smoky fires. Insulate all steam lines. Check proper
insulated. Steam traps not working. Sparkles in flame. Discharge of unburned trap operation periodically. Follow
Explosion. oil in furnace. Fireside explosion or puff. manufacturer's instructions.
Fire. Boiler damage. Property damage.
Loss of life and/or injury of personnel.

       
Worn or damaged atomizer (sprayer Abrasive material in oil. Normal wear. Fire. Incomplete or smoky combustion. Check tips regularly. Use copper tools to
plate). Leaving out of service burner tip hot Flare back. clean tips. Follow manufacturer's
furnace. Explosion. instructions. Replace gaskets when
cleaning or replacing tips. Do not use
copper tools for cleaning stainless steel
parts.

GAS FIRING
 Gas line leaks. Excessive pressure. Improperly Explosion. Fire. Asphyxiation. Color code piping. Adequate ventilation.
assembled joints. Damage to piping, Keep all piping, valves and fittings in
valves and fittings carrying fuel. Leaking good repair. Test for leaks before placing
gasket. equipment in operation. Avoidance of
use of pipes for supporting other
equipment or walking on. Warning
personnel o hazards so they will report
leaks promptly. Insure safety devices are
operative.
       
Gas relief valve or atmospheric vent Excessive pressure. Diaphragm rupture Normal vent discharge. Explosion. Fire. Loss of life or injury.
discharge. in regulators. Property damage. Pipe all relief valves
and vents to point of safe discharge.
       
Gas line repair. Damaged piping or valves Explosion. Fire. Loss of life or injury. Use accepted methods for purging and
Property damage. recharging gas lines. Follow NFPA 54.

       
Wet gas. Presence of distillate in gas Flameout and re-ignition. Explosion. Follow NFPA 54 for wet gas supply
Fire. Loss of life or injury. Boiler and system.
property damage.

       
Significant change in BTU rating of gas. Multiple gas sources with different Poor combustion. Explosion. Fire. Boiler Appropriate alarms. Use combustion
heating values. or property damage. Loss of life or controls that compensate for BTU
injury. changes.
       
High gas pressure Defective gas pressure regulator Fuel rich mixture. Fireside explosion. Monitor for regulator operation. Check
Fire. Loss of injury. Boiler or property operation and setting of pressure switch
damage. periodically. Repair or replace defective
regulators and switches.

       
STEAM LEAKS
Steam Leaks Damaged or corroded pipes and/or other Severe burns. Keep all joints and pipes tight. Warn
pressure parts personnel of hazards of invisibility of
superheated steam leaks.
       
HOT FLY ASH
Hot fly ash accumulations in boiler flues Severe burns to legs and other parts of Warnings to all personnel concerning this danger. Allow sufficient cooling time
and plenums. Fly ash accumulating in the body coming into contact with the before walking on fly ash. Remove the hot fly ash with caution and suitable
flues and plenums. Personnel stepping in hot fly ash. Overloading support systems equipment. Do not spray water on hot fly ash. Probe temperature of fly ash before
fly ash while still hot. Fly ash may retain causing failure. walking on it.
heat for a number of weeks. No visible
difference between hot and cold fly ash.
"Quicksand" action of fly ash when
stepped on. Explosive effect of water on
hot fly ash.

       
Steam Explosion
Defective safety valves. Obstruction between boiler and Will not lift to release excess Replace or repair safety valve.
valve. Valve damaged or corroded pressure. Impose excess pressure Remove obstructions. Periodically
(internal). Lever tied down. on the boiler. Rupture the boiler. test valve per ASME code.
Obstruction on valve outlet. Cause loss of life and/or injury to
personnel. Cause property damage.
       
Defective steam pressure gauges. Broken gauge. Gauge is not in Gauge is not showing the correct Calibrate gauge regularly. Replace
calibration. Blockage in line from pressure. Boiler may be under defective gauges. Inspect gauge
boiler to gauge. Gauge cock is excessive pressure. Prevents connection and piping to boiler for
closed. Multiple gauges not in operator from being aware of true blockage and/or closed cock.
agreement. operating conditions.
       
Low water level. Defective low water cutoff. Low water Overheated boiler surfaces. Verify operation of boiler water feed
cutoff bypassed. Improper water Ruptured boiler. Loss of life and/or system periodically. Prove low water
column blowdown procedure. injury to personnel. Property cutoff operation periodically. Use
Equalizing lines restricted or plugged. damage. proper water column blow down
Tampering with low water control. procedures. Train boiler operators.
Defective boiler water feed system. Do not tamper with low water
Operator error. Defective or controls. Replace defective low water
inoperative gauge glass. controls. Inspect equalizing line
(especially the lower line).

       
Scaled or corroded boiler internal Poor maintenance procedures. Ruptured boiler. Loss of life and/or Proper maintenance. Regular inspections
surfaces. Inadequate inspection. Improper injury to personnel. Property damage. by competent inspector. Keep inspection
chemical cleaning. Contaminated boiler Boiler overheating. log. Proper boiler water treatment.
water. Poor feed water control. Improper
water treatment.
       
 Bypassed controls. Defective electrical wiring. Tampering Controls will not function. Boiler may Verify proper operation of controls
with controls and electrical wiring. rupture. May cause furnace explosion. periodically. Correct electrical wiring
Loss of life. Property damage. defects immediately. Do not tamper with
controls.
       
Tampering with Controls Deliberate action by personnel. Lack of Improper operation of boiler. Boiler may Read and follow manufacturer's
knowledge on the part of the personnel. rupture. May cause furnace explosion. instructions. Prevent access by
Inadequate training. Loss of life. Property damage. unauthorized personnel by locking
equipment cabinet. Properly train
operators.
       
Poor maintenance. No definite maintenance policy and Danger to personnel and property. Low Establish a definite maintenance policy
procedure. Lack of interest of the boiler operating efficiency. Eventually high and procedure. Assign maintenance
owner. Poorly or inadequately trained repair and replacement costs. Poor responsibility. Insist on performance of
personnel. No one assigned the operation. maintenance functions. Keep
maintenance responsibility. maintenance log.
       
Condensate tank explosion. Improperly vented tank. Vent too small. Tank pressure may exceed design Eliminate traps in vent line. Eliminate
Vent is trapped. Frozen condensate in pressure. Tank may explode. Loss of life. restrictions in vent line. Vent to be full
trapped vent. Property damage. size (no valves). Vent to be run vertically
from tank.
       
FURNACE EXPLOSION
       
Inadequate pilot/igniter. Low gas pressure. Low oil pressure. May not ignite the main flame. Delayed Periodic pilot maintenance. Properly
Improperly positioned. Too small nozzle. ignition. Fireside explosion. Fire. Boiler position pilot, periodic pilot verification
Plugged orifice. Improper light-off damage. Loss of life and/or personal test. Use procedures of NFPA 85 series.
damper setting. injury. Property damage.
       
Delayed ignition. Inadequate pilot/igniter. Low fuel Fireside explosion. Fire. Boiler damage. Provide adequate pilot. Correct light-off
pressure. Insufficient fuel rate. Excessive Loss of life and/or injury to personnel. fuel/air ration setting. Avoid excessive
air rate. Low oil temperature. Water in Property damage. restart attempts. Review and follow
fuel. manufacturer's instructions. Conduct
pilot turndown test.
       
 Insufficient combustion air. Lack of or insufficient boiler room air Poor combustion. Delayed ignition. Provide adequate air to boiler room.
openings. Dirty combustion air blower. Fireside explosion. Loss of life and/or Keep combustion air fans clean and run
Combustion air blower running too slow injury to personnel. Property damage. at proper speed. Periodically observe
or slipping. Incorrect fuel/air ration Fire. Boiler damage. Increased dampers, air inlets and outlets,
setting. Blower inlet blockage. Outlet emissions. combustion controls boiler gas passages,
damper blockage. Plugged boiler gas hot flue gas passages, hot flue gas
passage. temperature.
       
Tampering with combustion safety Deliberate action by personnel. Lack of fireside explosion. Fire. Loss of life Review and follow manufacturer's
control. knowledge on the part of personnel. and/or injury to personnel. Boiler instructions. Prevent access by
Inadequate operator training. damage. Property damage. unauthorized personnel by locking
equipment cabinets. Train operators in
proper maintenance procedure.
       
Manual operation of combustion safety Deliberate action by personnel. May cause ignition of main flame at the Do not operate combustion safety control
controls. wrong time. Fireside explosion. Loss of manually. Review and follow
life or injury to personnel. Boiler manufacturer's instructions. Provide
damage. Property damage. Fire. adequate training for operators. Prevent
access of unauthorized personnel by
locking equipment cabinets.

       
Leaking fuel safety shutoff valves. Defective valve. Foreign matter under Fuel flows to the boiler. Uncontrolled Monitor valves for proper operation
valve seat. ignition of fuel. Fireside explosion. Loss periodically. Replace defective valves.
of life and/or injury to personnel. Boiler Leak test and verify proper operation of
damage. Property damage. Fire. valves periodically.
       
IMPLOSIONS
       
Excessive negative pressure. Flame out. Induced draft fan runaway. Equipment damage resulting in personnel Maintain proper operation of control
injury. equipment. Do not bypass control
equipment. Use procedures of NFPA
85G.

MAINTENANCE
       
Equipment being serviced or repaired. Equipment not locked out, not tagged Physical injury or death. Place the equipment if zero energy state
Unexpected starting of remotely out, not placed in zero mechanical state, or zero mechanical state. Establish and
controlled equipment. Movement of or not placed in zero energy state. comply with lockout and tagout
equipment. Release of electrical energy. procedures. Train and alert personnel.
Release of fluid pressure. Warning signs. Use blocking devices or
ties to prevent movement of equipment.
       
Activities related to cleaning. Failure to observe safety procedures Potential injury or death to personnel. Observe operating and maintenance
applicable to maintenance cleaning. instructions for maintenance cleaning.
Observe all safety regulations and normal
safety precautions. Provide a safe means
of access for maintenance cleaning.
Provide personnel with protective
clothing and equipment. Establish a
routine procedure to clean and remove
residue (ash, soot, slag) frequently to
prevent excessive accumulation. Report
all unsafe conditions and/or unsafe
practices.

       
Entering a confined or enclosed space Extremely hazardous environment I.e. Potential danger to life and health. Observe all safety regulations and normal
(includes but not limited to furnace, toxic or inflammable oxygen deficient safety precautions. Provide sufficient
drums, shell, gas passes, ducts, flues, atmosphere, hot material, darkness. ventilation to assure fresh air quality and
bunkers, hoppers, tanks). Temporary internal access provisions. quantity to maintain the health and safety
of personnel. Test for oxygen deficiency
with field type oxygen analyzers or other
suitable devices. Develop stand-by
emergency plans and procedures. Report
all unsafe conditions and/or unsafe
practices. Work with a partner. Test for
toxic or flammable gas. Provide lights
before entering a confined space.

       
 Oxygen deficiency Confined or enclosed spaces Potential danger to life or health. Provide sufficient ventilation to assure
fresh air quality and quantity to maintain
the health and safety of personnel. Wear
approved respiratory protective
equipment. Test for oxygen deficiency
with field type oxygen analyzers or other
suitable devices. Observe all safety
regulations and normal precautions.
Report all unsafe conditions and/or
unsafe practices.

       
Airborne contaminants I.e. gases, vapors, Leakage. Inadequate ventilation or Potential danger to life and health. Operate ventilation and exhaust systems.
fumes, dust, and mist. exhaust. Wear approved respiratory protective
equipment. Wear protective clothing.
Observe all safety regulations and normal
safety precautions. Report all unsafe
conditions and/or unsafe practices.

       
UNEXPECTED STARTING OF REMOTELY CONTROLLED EQUIPMENT
       
Expose moving equipment Guards not installed. Bodily injury. Dismemberment. Reinstall guards. Avoid loose clothes.
Confine long hair.
       
Exposed fan blades. Guards not in place. Bodily injury. Dismemberment. Reinstall guards.
       
Exposed moving parts of sootblowers. Guards not in place. Injured or lost fingers. Bodily harm. Reinstall guards. Avoid loose clothing.
Confine long hair.
       
Obstructed areas. Poor housekeeping. Potential injury to personnel. Provide a safe means of access to all
equipment and working places. Maintain
all access ways in a clean safe condition.

       
Lack of access to equipment. Access not provided. Potential injury to personnel. Provide a safe means of access to all
equipment and working places.
       
Accidental opening of the access door. Failure to bolt or lock closed door. Potential injury to personnel. Bolt or lock all access doors.
       
 ELECTRICAL
       
Exposed energized electrical wiring. Damaged insulation or protective Electrical shock resulting in death, Use care to prevent damaging insulation.
covering. injury, or burns. Repair damaged insulation.
       
Open electrical boxes. Failure to cover boxes. Electrical shock resulting in death, injury Cover boxes. Instruct personnel to keep
or burns. boxes covered.
       
Opening switch box without turning off Damaged safety catch permitting Electrical shock resulting in death, injury Repair safety catch. Turn off switch
power. opening without shutting off switch. or burns. before opening box. Don't tamper with
interlocks.
       
Working on energized electrical Second party closing switch which Electrical shock resulting in death, injury Follow lockout and tag out procedures.
equipment. energizes equipment. or burns.
       
Improper use of tools and lights. Lack of grounding. Cut off group prong. Electrical shock resulting in death, injury Don't cut off ground prong. Use only 3-
Using two wire extension cords. Not or burns. wire heavy-duty extension cords properly
grounding "cheater" plug (adapter plug). grounded. Ground "cheater" plug if used.
Body contact with wet surface. Damaged Use double insulated portable tools. Use
insulation. Using lights without guards. low voltage trouble lights or battery
operated lights. Make sue guard is
installed on light.
       
Combustible dust entering the electrical Not keeping dust proof equipment Death, injury or burns. Equipment Keep dust proof equipment closed.
equipment. closed. Poor housekeeping. damage. Explosion and/or fire. Practice good housekeeping procedures.
Insure proper operation of purge
equipment.

       
FIRE
       
Fire. Explosion. Electrical or mechanical Potential injury or death to personnel. Operate equipment in accordance with
failure. Improper operation of equipment. Potential equipment or property damage. manufacturers' recommended operating
Poor housekeeping. procedures. Conduct routine equipment
maintenance. Practice good
housekeeping. Report all unsafe
conditions and/or practices. Train and
drill operators in emergency firefighting
and extinguishing procedures. Use fire
protection systems.

       
Coal supply fire. Spontaneous combustion. Potential injury or death to personnel. Operate in accordance with the
Potential equipment or property damage. manufacturers recommended operating
procedures. Practice good housekeeping.
Report all unsafe conditions and/or
unsafe practices. Train and drill operators
in emergency firefighting control and
extinguishing procedures. Use fire
protection and/or inserting systems.
Proper coal supply.

       
Fire at burner deck, fuel stations, or other Electrical or mechanical component Potential injury or death to personnel. Operate equipment in accordance with
areas adjacent to the boiler. failure. Fuel leaks. Potential equipment or property damage. manufacturers recommended procedures.
Locate fuel, combustible materials, and
controls away from boiler surfaces.
Report all unsafe conditions and/or
practices. Train and drill operators in
emergency firefighting and extinguishing
procedures, Use fire protection systems.
Repair leaks promptly.
       
Wet steam during atomizing. Steam wet from source. Steam line not Poor atomization. Dirty or smoky fires. Insulate all steam lines. Check proper
insulated. Steam traps not working. Sparkles in flame. Discharge of unburned trap operation periodically. Follow
Explosion. oil in furnace. Fireside explosion or puff. manufacturer's instructions.
Fire. Boiler damage. Property damage.
Loss of life and/or injury to personnel.

       
Worn or damaged atomizer. (sprayer Abrasive material in oil. Normal wear. Fire. Incomplete or smoky combustion. Check tips regularly. Use copper tools to
plate.) Leaving out of service burner tip in hot Flare back. clean tips. Follow manufacturer's
furnace. Tip abuse. Explosion. instructions. Replace gaskets when
cleaning or replacing tips. Do not use
copper tools for cleaning stainless steel
parts.