SAFETY WORK: BOILER & PRESSURE VESSEL

Watch this video to have a short brief regarding safety work: boiler and pressure vessel before we learn much more about K3/OSHA on this specific topic ↴

Generally, a boiler is an enclosed vessel that provides a means for combustion and transfers heat to water until it becomes hot water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. A pressure vessel is a storage tank or vessel that has been designed to operate at certain pressures. Recent inspections of pressure vessels have shown that there are a considerable number of cracked and damaged vessels in workplaces. Cracked and damaged vessels can result in leakage or rupture failures. Potential health and safety hazards of leaking vessels include poisonings, suffocations, fires, and explosion hazards. Rupture failures can be much more catastrophic and can cause considerable damage to life and property. The safe design, installation, operation, and maintenance of pressure vessels in accordance with the appropriate codes and standards are essential to worker safety and health.

• LAWS AND REGULATIONS

1. UU Uap tahun 1930
2. Peraturan Uap tahun 1930
3. UU No. 1 tahun 1970 tentang Keselamatan Kerja
4. Permen No. 01/Men/1982 tentang Bejana Tekan
5. Permen No. 02/Men/1982 tentang Klasifikasi Juru Las
6. Permen No. 01/Men/1988 tentang Klasifikasi dan Syarat-syarat Operator Pesawat Uap

• SCOPE/ENVIRONMENT

Design consideration

The placement of steam boiler

Types of steam generator

Operation of steam aircraft

DESIGN CONSIDERATION

1. Construction drawings should be sufficiently clear and readable
2. The size of the aircraft and its parts should be clearly written
3. Drawing of section (detail) of connecting construction between one part to another must be specified, so the connection form is clearly known
4. The implementation of steam aircraft must meet the procedures in accordance with clear standards
5. Execution of vapor test must meet the applicable procedures

THE PLACEMENT OF STEAM BOILER

The steam boiler room is not a special place where it is uncertain to work. Steam boilers should be placed in a separate room or building from the other workplace.

TYPES OF STEAM GENERATOR

The difference between the steam boiler and the pressure vessel is from its function and operation. Steam boiler is a steam generator while the steam vessel is a steam receiver in the course of a process that uses steam installations.

OPERATION OF STEAM AIRCRAFT

In order for the maintenance of the boiler, it is necessary to conduct education and training on steam boiler operators, steam welders, such as steam boiler operator education and training and welding training.

• SOURCE OF HAZARDS AND THE CONSEQUENCES

1. HAZARDS ON STEAM AIRCRAFT

- Manometer does not work well will cause explosion.

- Safety valve does not work resulting in excessive tackling.

- Unfinished glass leads to an uncontrolled amount of water.

- Water boiler filler does not work to cause vessel boiling due to lack of heat transfer.

2. HAZARDS ON PRESSURE VESSEL

- Fire.

- Toxicity and irritation.

- Choking in breathing.

- Blasting.

- Infected with very cold fluid (cryogenic).

• DEVELOPMENT AND MANAGEMENT

1. Guidelines for implementation of inspection, testing and publication of steam license

- The aims of activities in the implementation of examination and testing

- The aims of activities in the issuance of license usage

- Inspection and testing procedures

- Procedure of issuing permit for steam aircraft

2. Guidelines on implementation of testing and publishing the use validation of pressure vessel

- Examinations and tests are performed by K3 specialist in steam engine and pressure vessel.

- Safety requirements must be adhered to a pressure vessel and the technical provisions of the execution of inspection and testing activities and verification of the use of pressure vessels, shall comply with applicable laws and regulations.

• STUDY CASE

On December 7, 2009, at approximately 2:30 pm, State Special Vessel No. 2, under an

operating pressure of 29,000 psig, suddenly and violently ruptured, 120 days into a 150-day operating cycle. A white cloud of steam and debris rapidly expanded outward from the facility, traveled onto the interstate, and dissipated within seconds. The sudden release of superheated liquid caused an eight-foot tall by four-foot wide vessel fragment, weighing approximately 8,600 pounds, to travel through two concrete walls and finally land about 435 feet from the NDK building. The fragment skipped across a neighboring facility parking lot and slammed into the wall of an adjacent business office. The force of the impact pushed the wall inward causing furniture to shift and ceiling tiles to fall. One person working near the wall was injured. The thrust from the escaping liquid caused the base of the vessel to violently shear away from its foundation and blew pieces of structural steel out of the building into the parking lot of a nearby rest stop gas station, known as the Illinois Tollway (I-90) Oasis. One piece of structural steel struck and killed a truck driver at the rest stop. After shearing from its base and throwing shrapnel out of the facility, the vessel swung from the building and landed on the ground outside. At the time of the incident, a member of the public was leaving the I-90 Tollway Oasis and returning to his truck when he was struck by a flying fragment propelled by the force of the vessel explosion. The seven-foot, 100-pound steel beam from the NDK facility traveled about 650 feet, and struck and killed the truck driver. An employee at Grupo Antolin, an adjacent automotive supply company, received minor injuries because of the impact from the 8,600-pound vessel fragment against the exterior wall of the office area. Emergency medical services evaluated and treated the Grupo Antolin employee on-scene. Six NDK Crystal employees were present in the production area at the time of the explosion, but were uninjured.