The document outlines various safety measures and controls for boilers to reduce hazards and ensure safe operation. Key measures include: 1) Remnant Life Assessment of pressure parts and inspection of safety valves to assess condition. 2) Condition monitoring using NDT techniques like ultrasonic testing and hardness testing to inspect deposits and weld joints. 3) Destructive testing of sample tubes during overhauls and regular monitoring of tube thickness. 4) Ensuring protection systems are properly functioning by simulating scenarios to check the maintenance and testing system.

1. Boiler Safety Measures
By:
Prakash.R
AP/FT

2. Measures taken to reduce the
hazards ensuring the safe and
reliable working
• Remnant Life Assessment ( RLA ) of
boiler pressure parts ,also a legal
requirement for unit,which have
completed 1 lakhs operating hours OR
15 years in service, which ever is earlier.
• Inspection and certification of the safety
valves

3. Measures taken to reduce the hazards ensuring
the safe and reliable working
• Conditioning monitoring of the boiler by
using NDT Techniques like inspection of
deposits in tubes of different
sections,hardness testing,Dye penetrate
and ultrasonic testing of weld joints.
• Trivi test; by increasing drum pressure

4. Measures taken to reduce the hazards ensuring
the safe and reliable working
• Destructive testing of sample tubes
during overhaul of boiler.( tensile test )
• Regular monitoring of tube
thickness,tube scanning and advance
techniques like LFED ( Low frequency
Electrodynamic Device.)

5. Measures taken to reduce the hazards ensuring
the safe and reliable working
• Ensuring proper protection by periodic
checks by simulating or relevant
procedures.( At the end of the outage
simulating scenarios / faults & checking
MFT and checking healthy working of
protection.)
• Hydro testing of boiler once in a year

6. Controls for boiler in service -
• Permissive for boiler purging prior to lightup.(
By using FD&ID fans to clear all explosive
mixture if any)
• Flame scanners-for detecting the flames of
the burners.( Sensing the flame by UV
sensors)
• Furnace draft control to avoid explosion /
implosion of boiler / ductings.
• Various other controls for monitoring feed
flow,combustion control etc

7. Controls for boiler in service -
• Acoustic sensors to detect the sound of the
tube leak in the furnace.
• Alarms and monitoring and controls to
maintain the water chemistry.
• Alarms and monitoring metal temperature of
pressure parts.( Water chemistry,pH
value,unwanted chemicals such as Silica)
• Gas Leak detection system in the firing aisle
of boiler and near gas station.

8. Controls for boiler in service -
• Regular house keeping reports and
checks.
• Provision for installing the rupture disc
in coal mill inlet air ducts is in progress
(Inside coal mill air inlet duct as
certified by NFPA )
.