This document discusses hazards related to burns and hot condensate. It outlines objectives to recognize hazards from steam and hot condensate, identify potential consequences, describe control actions, and identify burn severity and first aid treatments. Examples of incidents involving burns from condensate and steam are provided. Precautions to prevent contact with hot condensate include guiding it away from occupied areas, barricading, and properly securing discharge hoses. The document also reviews different levels of burn severity and first aid treatments for minor and major burns.

1. Hazard Recognition
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Burns and Hot Condensate

2. Hazard Recognition
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Burns and Hot Condensate
Objectives:
Upon completion of this module, the participant will be able to:
 Recognize the hazard posed by the several heat sources
present in the plant with particular attention to steam and
hot condensate
 Identify the potential consequences associated with
hazards related to steam and hot condensate
 Describe actions required to control the hazards
associated with steam and hot condensate
 Identify the three levels of burn wound severity
 Identify the first aid actions for treating burn wounds

3. Hazard Recognition
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Burns and Hot Condensate
Key Principles
 Several accidents (burn wounds) with serious
consequences are recorded each year due to contact with
hot condensate or exposure to steam
 Hazard posed by steam and hot condensate should be
identified and the risk reduced using systems already in
place in all units, such as Last Minute Risk Assessment,
Work Permit, etc.

4. Hazard Recognition
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Burns and Hot Condensate
 Discharging hot condensate to the sewer
 The rope holding the drain hose became loose
 The operator is splashed by the jumping drain hose
 A burn results

5. Hazard Recognition
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Burns and Hot Condensate
Other Incidents
 An employee is performing routine
work and opens a valve on a steam
line.
 Condensate sprays out of another
valve that was inadvertently left
open
 A burn results

6. Hazard Recognition
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Burns and Hot Condensate
Other Incidents
 An employee was attempting to
unplug a drain line that was located
below a steam safety valve.
 Pressure on the system built up
 Safety valve released, causing a
spray of hot water to be emitted from
the exhaust
 Employee was burned

7. Hazard Recognition
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Burns and Hot Condensate
Other Incidents
 In private situations, contact with hot boiling water (especially
children) in the kitchen is daily business!

8. Hazard Recognition
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Burns and Hot Condensate
Special Note: Overheated Steam
What is dangerous about overheated steam?
Answer: It’s very hot and you can't see it!!!

9. Hazard Recognition
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Burns and Hot Condensate
Why Is Hot Condensate Dangerous?
We worry about hot hydrocarbons / chemicals and additives but
condensate is only water !
(We Think)!!

10. Hazard Recognition
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Burns and Hot Condensate
Why Is Hot Condensate Dangerous?
 Burn wounds start to develop when
there is contact with temperatures as
low as 140 °F (60 °C)
 3 barg steam is already 248 °F
(120 °C)
 40 barg steam is 716 °F (380 °C)
(Data from American Burn Association)
Time and Temperature Relationship to
5.
3.8
2.5
1.3
0.
Serious Burns
130 140 150 160 170 180 190 200 210
Time (sec)
Temperature (°F)
5 sec
2 sec
1 sec
0.5 sec
 The degree (1st, 2nd of 3rd) of burn
wounds depends on temperature,
duration of contact and energy
capacity of the product that causes
the burn.
 So contact with steam often results in burn wounds even though PPE
may be worn

11. Hazard Recognition
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Burns and Hot Condensate
Why Is Hot Condensate Dangerous?
 Steam traps contain condensed steam often at 194 °F (90 °C)
and always above 167 °F (75 °C) - so the potential for burn
wounds is always present.
 Hot condensate has a greater (energy) capacity to cause burn
wounds than steam.

12. Hazard Recognition
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Burns and Hot Condensate
Equipment / Location Where The Contact Is
Possible
 Atmospheric condensate drums
 Steam drums
 Atmospheric exhausts from
turbines or other equipment
 Silencers from turbines of other
equipment
 Steam traps

13. Hazard Recognition
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Burns and Hot Condensate
Equipment / Location Where The Contact Is
Possible
 Condensate drains used for winterizing
 Excessive draining or leakage can result in pools of hot condensate
accumulating at grade and filling holes, sumps, low points, etc.
 ……and more (add yours)
 Locations where hot condensate is being
temporarily discharged / drained
 Locations where equipment is being
purged with steam
 Uninsulated sections or damaged
insulated sections of:
– Steam lines
– Condensate lines
– Steam tracing

14. Hazard Recognition
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Burns and Hot Condensate
Precautions To Prevent Contact
 If it is necessary to discharge hot condensate to an open
system, the following precautions can be taken:
 Guide the hot condensate to an area not normally occupied by
people.
 Barricade / segregate the area if possible.
 Place signs to alert personnel and communicate the hazard to
affected personnel.
 Remark the hazard in work permits and LMRA
 Steam hoses should be properly secured when used for routing the
condensate.
 Hot condensate should not be discharged in locations where light
hydrocarbons and high vapor pressure chemicals (flammables or
dangerous to health or simply bad smelling) might be present to
avoid excessive evaporation

15. Hazard Recognition
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Burns and Hot Condensate
Precautions To Prevent Contact
 Winterizing is of special concern:
– Release of hot condensate is increased
 Special precautions are necessary when:
– Commissioning steam tracing
– Troubleshooting steam trap and tracing
failures
– Draining accumulations of hot condensate
– Discharging steam to atmosphere

16. Hazard Recognition
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Burns and Hot Condensate
Precautions To Prevent Contact
 Steam traps might temporarily plug; the pressure build- up
can result in a sudden / violent release of hot condensate
with potential for splashing in the surroundings

17. Hazard Recognition
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Burns and Hot Condensate
Precautions To Prevent Contact
 Steam is used to heat hydrocarbons and
chemicals:
– Insulation for protection against accidental
contact with hot piping and surfaces is done
only where presence of personnel is routine.
– Viscous hydrocarbons and chemicals will
adhere to fabric and skin:
• The severity of burn wounds might increase due
to the prolonged heat transfer
• Do not attempt to remove the product adhering to
skin to avoid tearing the skin

18. Hazard Recognition
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Burns and Hot Condensate
How To Protect Yourself
 Know where the risks are on your unit(s).
 Make sure steam and condensate systems on your unit(s)
are well maintained.
 Make sure that steam trap drain / tail lines are tied down so
that they cannot injure someone when they discharge.
 When preparing work in the field or practicing LMRA before
start of work, check for location of steam traps and
discharge direction vs yourself.
 Be on the lookout for new hazards that are caused by steam
and condensate as the units are being prepared for winter
operations.
 Know what to do if you are burned and the location of safety
showers. At first, flush with a lot of (normal temperature)
water for at least 15 minutes. Quick response may minimize
the severity of the burn.

19. Hazard Recognition
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Burns and Hot Condensate
Burns: Memory Refresher
 Burns can be caused by dry heat (like fire), wet heat (such
as steam or hot liquids), radiation, friction, heated objects,
electricity, or chemicals.
 Thermal burns are the most common type. Thermal burns
occur when hot metals, scalding liquids, steam, or flames
come in contact with your skin.

20. Hazard Recognition
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Burns and Hot Condensate
Burns: Memory Refresher
 Burns to your airways can be caused by inhaling smoke, steam,
superheated air, or toxic fumes, often in a poorly ventilated space

21. Hazard Recognition
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Burns and Hot Condensate
Burns: Memory Refresher
 There are three levels of burns:
 First-degree burns affect only the outer layer of the skin. They cause
pain, redness, and swelling.
 Second-degree (partial thickness) burns affect both the outer and
underlying layer of skin. They cause pain, redness, swelling, and
blistering.
 Third-degree (full thickness) burns extend into deeper tissues. They
cause white or blackened, charred skin that may be numb.

22. Hazard Recognition
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Burns and Hot Condensate
First Aid - For Minor Burns
 If the skin is unbroken, run cool water over the area of the burn
or soak it in a cool water bath (not ice water).
 Keep the area submerged for at least 5 minutes.
 A clean, cold, wet towel will also help reduce pain.
 Calm and reassure the person.

23. Hazard Recognition
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Burns and Hot Condensate
First Aid - For Minor Burns
 After flushing or soaking, cover the burn with a dry, sterile
bandage or clean dressing.
 Protect the burn from pressure and friction.
 Once the skin has cooled, moisturizing lotion also can help.

24. Hazard Recognition
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Burns and Hot Condensate
First Aid - For Minor Burns
 Minor burns will usually heal without further treatment.
 However, if a second-degree burn covers an area more than 2
to 3 inches in diameter, or if it is located on the hands, feet,
face, groin, buttocks, or a major joint, treat the burn as a major
burn.
 Do not take any medicine (other than pain reliever if required)
without seeking medical attention

25. Hazard Recognition
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Burns and Hot Condensate
First Aid - For Major Burns
 Call site or local medical emergency
immediately
 DO NOT remove burnt clothing or
product that is stuck to the skin.
 DO NOT apply any ointments. Avoid
breaking burn blisters.
 Make sure the person is breathing. If
breathing has stopped, or if the
person's airway is blocked, open the
airway. If necessary a trained person
can begin rescue breathing and CPR.

26. Hazard Recognition
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Burns and Hot Condensate
First Aid - For Major Burns
 Cover the burn area with a dry sterile bandage (if available) or
clean cloth. A sheet will do if the burned area is large.
 If fingers or toes have been burned, separate them with dry, sterile, non-adhesive
dressings.
 Elevate the body part that is burned above the level of the heart. Protect
the burnt area from pressure and friction.
 Take steps to prevent shock. Lay the person flat (but NOT if a head, neck,
back, or leg injury is suspected) elevate the feet about 12 inches, and
cover with a coat or blanket. Continue to monitor the person's vital signs
until medical help arrives.

27. Hazard Recognition
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Burns and Hot Condensate
Objectives Review:
Upon completion of this module, the participant will be able to:
 Recognize the hazard posed by the several heat sources
present in the plant with particular attention to steam and
hot condensate
 Identify the potential consequences associated with the
hazards related to steam and hot condensate
 Describe actions required to control the hazards
associated with steam and hot condensate
 Identify the three level of burn wounds severity
 Identify the first aid actions for treating burn wounds