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Discover the principles and regulations for occupational safety when operating boilers. This document provides detailed guidance and risk prevention measures, helping you to understand the process and improve safety in your work environment.

Table of Contents

PART I: CURRENT STATUS OF SAFETY WORK RELATED TO BOILERS

I. General Situation

The Ministry of Labour, Invalids and Social Affairs informs sectors and localities of the occupational accident situation in the first 6 months of 2024 and outlines key solutions to proactively prevent incidents and accidents in the last 6 months of 2024. According to reports from 61 out of 63 centrally governed provinces and cities, in the first 6 months of 2024, there were a total of 3,201 occupational accidents nationwide (a decrease of 227 cases, equivalent to 7.09% compared to the same period in 2023), resulting in 3,065 victims (a decrease of 197 people, equivalent to 6.04% compared to the first 6 months of 2023), including both employees under labor contracts and those working without labor contracts. Specifically:

Number of fatal occupational accidents: 320 cases, a decrease of 25 cases (7.25%) compared to the first 6 months of 2023 (including 245 cases in areas with labor relations, a decrease of 28 cases or 10.3%; and 75 cases in areas without labor contracts, an increase of 3 cases or 4.2% compared to the first 6 months of 2023);
Number of deaths due to occupational accidents: 346 people, a decrease of 7 people or 1.98% compared to the same period in 2023 (including 268 in areas with labor relations, a decrease of 13 people or 4.63%; and 78 in areas without labor contracts, an increase of 6 people or 8.33%).
Number of people seriously injured: 810 people, an increase of 26 people or 3.32% compared to the first 6 months of 2023 (including 710 in areas with labor relations, a decrease of 5 people or 0.7%; and 100 in areas without labor contracts, an increase of 31 people or 44.92%).

Download the PDF file Occupational Accident Report – First 6 Months of 2024 issued by the Ministry of Labour, Invalids and Social Affairs.

The occupational accident situation in the first 6 months of 2024 in both sectors with and without labor relations saw a decrease in the number of deaths and fatal accidents compared to the same period in 2023.

II. Some occupational accidents when operating a Boiler

In industry, the operation and maintenance of boilers are a crucial part of ensuring employee safety and are also a determining factor in production efficiency. However, many occupational accidents related to boilers have occurred for various reasons. Below are some common accidents when operating a boiler that need attention:

Boiler explosion: One of the most dangerous accidents when operating a boiler is an explosion. Causes can include excessively high pressure, failures in the valve and safety valve system, or a loss of control over temperature and pressure.
Risk of poisoning: During boiler operation, many types of chemicals and harmful gases are used or produced. Unsafe contact with these substances can cause serious health problems for employees, including inhaling toxic vapors, skin contact, or eye contact.
Accidents due to lack of knowledge and skills: A lack of understanding and skills in operating a boiler can lead to accidents because workers do not know how to handle dangerous situations or do not follow safety procedures correctly.
Hot steam leaks: Hot steam leaks from a boiler can cause burns to employees or lead to problems with the work safety system.
Unsafe motors and machinery: If not regularly maintained and safety checked, the mechanical parts and machinery in the boiler system can cause accidents due to failure or falling parts.
Lack of protective systems: Boilers need to be equipped with safety protection systems such as temperature sensors, safety valves, and warning systems to prevent dangerous incidents.

To minimize the risk of occupational accidents when operating a boiler, training and coaching employees, regular maintenance, and adherence to safety procedures are very important. At the same time, the use of new technology and automated monitoring systems can also help to enhance safety for the entire boiler operation process.

PART II: OCCUPATIONAL SAFETY AND HEALTH WHEN OPERATING A BOILER

I. Introduction

A. Overview of the importance of occupational safety when operating a Boiler

Occupational safety when operating a boiler is a crucial factor that not only ensures the protection of employees but also directly affects the operational efficiency of the entire production system. In an industrial environment, boilers are often an indispensable part, but if not operated and maintained correctly, they can become a significant risk to the health and safety of employees as well as the company’s assets.
Maintaining a safe working environment when operating a boiler not only minimizes the risk of occupational accidents but also helps to enhance the reliability of the system. Safety measures such as training employees on safety procedures, using protective equipment, and adhering to relevant regulations and guidelines all need to be implemented seriously and regularly.
In addition, ensuring occupational safety when operating a boiler also contributes to maintaining the reputation and image of the business in the eyes of customers and the community. A safe working environment is not only a legal responsibility but also an important factor in attracting and retaining talented employees.

B. Important safety protocols and regulations when operating a Boiler

To ensure the safety of employees and the system, adhering to safety protocols and regulations when operating a boiler is extremely important. In industry, many standards and guidelines have been established to guide businesses in implementing safety measures when working with boilers.
One of the common protocols is to comply with regulations on periodic maintenance and safety inspections. This includes conducting periodic checks on the pressure, temperature, and protective systems of the boiler to ensure they are operating effectively and safely.
In addition, training and coaching employees on the use of protective equipment and safety procedures is also an important part of safety protocols. Employees need to know how to react and respond to dangerous situations, as well as how to prevent them.
Furthermore, adherence to legal regulations and industry standards is also an indispensable part of safety protocols. This includes complying with regulations on emissions, electromechanical safety, and standards for water quality and chemicals used in the boiler operation process.

II. Components and Functions of a Boiler

A. The different components of a Boiler

Furnace: The furnace is the part of the boiler where fuel is burned to generate high temperatures. The type of fuel used can be oil, gas, coal, or biomass fuels.
Steam Drum: The steam drum is where steam is generated and stored before being controlled and distributed to various end-use processes. It can also be used to separate steam and vapor.
Piping System: The piping system in a boiler is responsible for conveying steam or vapor from the furnace to other equipment and processes. The piping needs to be designed and maintained to ensure maximum safety and efficiency.
Control and Safety Devices: These devices include safety valves, pressure sensors, control valves, and automatic controllers. They help regulate the boiler’s operation and protect against risks such as overpressure, overheating, and steam leaks.

B. Structure and operating principle of a Boiler

A boiler is an important piece of equipment in industry and utilities, responsible for generating steam or vapor that can be used for many different purposes. The structure of a boiler typically includes a furnace, a steam drum, a piping system, and control devices.
The furnace is the main part of the boiler, where fuel is burned to create thermal energy. This combustion process generates thermal energy that is transferred to the water in the steam drum, turning the water into steam. The generated steam is then conducted through the piping system to the equipment and processes where it is used.
The operating principle of a boiler is based on converting energy from fuel to water, and then from water to steam. This conversion process typically uses the thermal energy generated from burning fuel to create high-pressure and high-temperature steam or vapor.
To ensure the safe and efficient operation of the boiler, control and safety devices such as safety valves, pressure sensors, and control valves play a crucial role in monitoring and regulating the boiler’s operation.

C. Applications in the manufacturing industry of a Boiler

Power generation: In the power generation industry, boilers are used to create steam or vapor to operate power-generating turbines.
Chemical production: In the process of chemical production, boilers are often used to supply steam or vapor to create chemical products.
Pulp and paper production: Boilers are used to supply steam to soften and process raw materials like wood and pulp in the papermaking process.
Food and beverage production: In the food and beverage industry, boilers are used to supply steam for distillation, cooking, and drying products.
Oil and gas production: In the oil and gas production process, boilers can be used to generate steam or vapor for use in the processing of oil and natural gas.

D. Risks associated with operating a Boiler

Operating a boiler can carry significant risks if not done carefully and safely. Some common risks associated with operating a boiler include:

Risk of boiler explosion: If the pressure or temperature in the boiler is not controlled or monitored closely, there can be a risk of a boiler explosion, causing severe damage to both personnel and property.
Hot steam leaks: Hot steam leaks from a boiler can cause burns to personnel and lead to fires or damage to facilities.
Risk of poisoning: During operation, a boiler can produce harmful gases or other by-products, posing a danger to the health of personnel if not handled correctly.
Lack of knowledge and skills: A lack of knowledge and skills in operating a boiler can lead to unexpected incidents and occupational accidents as personnel do not know how to handle dangerous situations.
Lack of maintenance and periodic inspection: Neglecting periodic maintenance and safety inspections can lead to system failures and reduce the operational efficiency of the boiler.

III. Safety Inspection and Maintenance Before Operating a Boiler

A. Safety inspection before operating a Boiler

Before operating a boiler, conducting a safety inspection is an extremely important step to ensure that the system operates safely and effectively. The safety inspection steps typically include:

Check pressure and temperature: Ensure that the pressure and temperature in the boiler are at safe levels before starting or putting it into operation. Check the pressure and temperature monitoring devices to ensure they are working correctly.
Check the safety valve system: Identify and check the safety valve system to ensure it is functioning correctly and can release pressure if necessary to prevent the risk of a boiler explosion.
Check the water supply and water treatment system: Ensure that the water supply system to the boiler and the water treatment system are both operating effectively to prevent incidents such as water leaks or pipe blockages.
Check the piping system and accessories: Inspect all pipes and accessories to ensure they are not damaged or leaking, and also to ensure they can withstand the pressure and temperature of the operating process.
Check control and safety devices: Ensure that all control and safety devices such as control valves and sensors are operating correctly and are properly calibrated.

By performing these safety inspection steps before operating the boiler, we can ensure that the operation proceeds safely and reliably, minimizing the risk of accidents and unwanted incidents.

B. Guide to periodic maintenance of a Boiler

Regular inspection and cleaning: Perform regular inspection and cleaning of the boiler parts, including the furnace, steam drum, and piping system. Removing scale and other contaminants can help improve operational efficiency and extend the life of the boiler.
Check valves and safety equipment: Ensure that safety valves and other safety equipment such as control valves and pressure sensors are working correctly and are properly calibrated.
Replace worn components: Replace worn or damaged components such as seals, valves, and sensors on a regular schedule. This helps keep the boiler operating stably and avoids unwanted incidents.
Inspect and maintain the combustion system: Inspect and maintain the combustion system regularly to ensure that the fuel is burned efficiently and safely.
Inspect the water supply and water treatment system: Inspect and maintain the water supply and water treatment system regularly to prevent incidents such as water leaks or pipe blockages.

IV. Safe Operating Procedure for a Boiler

A. Step-by-step guide on the safe operating procedure for a Boiler

A safe boiler operating procedure is an indispensable part of any production activity. Below is a step-by-step guide on a safe boiler operating procedure:

Pre-operation check: Before starting the boiler, check the entire system from the outside, including checking the pressure, temperature, and safety valves. Ensure that there are no signs of leaks or damage to the system.
Starting the boiler: Start the boiler according to the manufacturer’s instructions or the company’s guidelines. Ensure that the start-up procedure is carried out correctly and safely.
Monitor operation: Monitor the boiler’s operation throughout the process. Track the pressure, temperature, and other parameters of the boiler to ensure it is operating within a safe range.
Handle incidents: If any incidents such as a sudden pressure increase or a leak are detected, immediately stop the boiler’s operation and take corrective measures. Always follow safety procedures in the event of an incident.
Perform periodic maintenance: Perform periodic maintenance steps according to the schedule recommended by the manufacturer or by the company itself. Ensure that the boiler is always properly maintained to sustain performance and safety.

Following these steps in the boiler operating procedure will help ensure that the operation is conducted safely and effectively, minimizing the risk of incidents and protecting the employees as well as the company’s assets.

B. Emergency handling measures and incident response mechanisms when operating a Boiler

Stop boiler operation: Immediately stop the boiler operation upon detecting any incident, such as a sudden pressure increase, water leak, or gas smell. This is the first and most important measure to prevent serious consequences.
Activate the safety system: Activate safety devices such as safety valves to reduce pressure or pressure sensors to minimize the risk of a boiler explosion or pressure-related incidents.
Move personnel out of the hazardous area: Guide personnel to leave the hazardous area safely and quickly. Ensure they are trained on safety measures and responses in case of an emergency.
Call the emergency number immediately: When a serious incident occurs, call the emergency number immediately and report the situation, while also requesting assistance from fire and rescue teams.
Take corrective and repair measures: After ensuring safety, take corrective and repair measures to resolve the incident and return the boiler to safe operation.

V. Risk Assessment and Hazard Management When Operating a Boiler

A. Identifying potential risks and hazards in operating a Boiler

Risk of boiler explosion: Excessively high pressure in the boiler can lead to the risk of a boiler explosion, causing severe damage to surrounding personnel and property.
Hot steam leaks: Hot steam leaks from the boiler can cause burns to personnel and lead to fires or damage to the facility.
Poisoning: The process of burning and handling fuel can create toxic gases, posing a danger to the health of personnel.
Equipment failure: Incidents or failures of devices in the boiler such as valves, sensors, or controllers can lead to unstable operation or a risk of failure.
Lack of maintenance: A lack of periodic maintenance can lead to the accumulation of scale, pipe blockages, and reduced operational efficiency of the boiler, increasing the risk of failure.

B. Effective hazard prevention strategies when operating a Boiler

1. Regular inspection and maintenance of the Boiler for safe operation

Check pressure and temperature: Check and evaluate the operating pressure and temperature of the boiler to ensure they are within a safe range. This usually involves using accurate pressure and temperature measuring devices.
Check the piping and valve system: Check and control the system’s pipes and valves to detect any signs of leaks or damage. Ensure that all valves are functioning correctly and are not stuck.
Clean the boiler: Remove accumulated scale and impurities in the boiler by cleaning parts such as the furnace and steam drum. This helps to improve efficiency and reduce the risk of incidents.
Inspect and maintain the combustion system: Inspect and maintain the parts of the combustion system, including checking and cleaning the combustion chamber and checking for cracks or damage.
Replace worn components: Replace worn or damaged components such as seals, valves, and sensors on a regular schedule.

2. Adherence to occupational safety regulations for the safe operation of a Boiler

Training and instruction: Ensure that all personnel involved in boiler operation are fully trained on safety procedures, accident prevention measures, and how to respond in an emergency.
Use of protective equipment: Require all personnel to use full protective equipment such as helmets, safety glasses, and reflective vests when working near a boiler to protect against the risk of accidents.
Do not exceed safe load capacity: Limit the transport and handling of fuel or materials around the boiler to ensure that the safe load capacity for the system is not exceeded.
Report incidents: Require all personnel to immediately report any incidents or hazardous situations they encounter during boiler operation.
Perform regular inspection and maintenance: Ensure that all regular inspection and maintenance measures are carried out correctly and fully to minimize the risk of incidents.

3. Identifying and marking the safe zone when operating a Boiler

Identify hazardous zones: First, identify the zones in the boiler operating area that have a high risk of high temperature, high pressure, or chemical impact. These are usually the areas near the boiler, hot water pipes, or combustion equipment.
Establish a safe zone: Based on the identified hazardous zones, establish surrounding safe zones. Ensure that these safe zones are wide enough to be far from the risks of temperature, pressure, and other impacts that can occur from the boiler.
Mark the safe zone: Use signs, road markings, or other marking means to clearly indicate the safe zones. Ensure that the signs are placed in easily visible and accessible locations for all personnel working in the area.
Training and reminders: Ensure that all personnel are trained on the safe zone and know how to identify and comply with safety measures when working around the boiler.

4. Use of personal protective equipment when operating a Boiler

Helmet: A helmet provides protection for the head and brain of employees from the risk of impact and falling heavy objects from above.
Safety glasses: Safety glasses help protect the eyes from dust particles, debris, and harmful chemicals that may be present during boiler operation.
Heat-resistant gloves: Heat-resistant gloves provide protection for the hands and wrists from high temperatures, chemicals, and toxic materials when working near a boiler.
Reflective vest: A reflective vest helps to make employees stand out in a dark work environment and reduces the risk of collision with moving vehicles.
Safety shoes: Safety shoes with non-slip and puncture-resistant soles help protect the feet and toes from accident risks during boiler operation.

5. Emergency procedures and response in case of an incident when operating a Boiler

Stop boiler operation: Immediately stop the boiler operation upon detecting any sign of an incident, such as a sudden pressure increase, a leak, or a gas smell.
Protect personnel: Guide personnel to leave the hazardous area safely and quickly. Ensure that they follow safety measures and do not come into direct contact with the hazard.
Call the emergency number: Call the emergency number immediately and report the incident. Provide detailed information about the location and severity of the incident.
Activate the safety system: Activate safety devices such as safety valves to reduce pressure or pressure sensors to minimize the risk of a boiler explosion or pressure-related incidents.
Take corrective measures: After ensuring safety, take corrective and repair measures to resolve the incident and return the boiler to safe operation.

6. Participate in occupational safety training courses when operating a Boiler

Occupational safety and health training is not only a legal requirement but also a commitment to the safety and health of workers. It helps employees recognize and deal with risks and hazardous situations, thereby reducing accidents, injuries, or fatalities in their daily work.
The risk of accidents is always present and can occur at any time in the work environment due to the possibility of human error and the unpredictability of all situations. This emphasizes the need for occupational safety training and continuous vigilance.
When participating in occupational safety training at Nam Viet Safety Center, workers will be systematically trained from theory to real-life risk scenarios. Accordingly, there will be measures to identify and prevent occupational accident risks that may occur during work. After the training course, trainees will take occupational safety tests to obtain an occupational safety certificate. From there, workers will have a clear understanding of safety knowledge as well as a valid certification for employment.

VI. Factors Affecting Occupational Safety When Operating a Boiler

A. How do weather conditions affect the operation of a Boiler?

Temperature: The ambient temperature can affect the boiler’s operating efficiency. In cold weather, the boiler may lose more energy to maintain the required temperature and pressure, while in hot weather, the boiler may have difficulty cooling and maintaining a stable pressure.
Humidity: High humidity can cause corrosion and affect the boiler’s materials, especially if there are no appropriate preventive and maintenance measures. Water can accumulate in the boiler’s pipes and surfaces, causing rust and affecting its operating efficiency.
Wind: The speed and direction of the wind can affect the boiler’s combustion and cooling process. Strong winds can reduce combustion and cooling efficiency, while wind blowing into the boiler can increase the risk of incidents and create unwanted effects.
Rain and snow: Rain and snow can cause problems for the boiler’s cooling system if not properly maintained. Water can cause dampness and accumulation, leading to a risk of leaks and breakdowns.

B. How does the working environment affect the operation of a Boiler?

Humidity: A work environment that is too humid can cause corrosion and rust on the boiler’s surface, leading to breakdowns and reducing the equipment’s lifespan. Water accumulation in the boiler can also cause a risk of leaks and reduce operational efficiency.
Dust and pollution: A work environment polluted with dust, chemicals, or other impurities can cause blockages and damage to the boiler’s parts, affecting the combustion and cooling process.
Temperature: A work environment with high or low temperatures can both affect the boiler’s efficiency and effectiveness. Excessively high temperatures can cause water loss and damage to mechanical parts, while excessively low temperatures can reduce combustion and cooling efficiency.
Photosynthesis: Strong light or UV rays can affect the boiler’s materials, causing rapid corrosion and wear.
Air: A work environment with limited oxygen or containing toxic gases can affect the combustion process and pose a health hazard to employees.

C. How does the technical condition of the Boiler affect its operation?

The technical condition of the boiler plays a crucial role in ensuring the safe and efficient operation of the system. The boiler needs to be periodically maintained and inspected to ensure that its components and parts are functioning correctly. If the boiler experiences an incident or breakdown, this can affect the production process and the safety of employees.
Technical issues such as water leaks, rust, and failures of the controller and safety valve can pose a risk of accidents and reduce the boiler’s operational efficiency. Therefore, maintaining the good technical condition of the boiler through periodic maintenance and timely repairs is extremely important to ensure the safe and effective operation of the boiler.

D. How do the safety knowledge and skills of the worker affect the operation of a Boiler?

The safety knowledge and skills of the worker play a crucial role in ensuring safety and efficiency when operating a boiler. Employees need to be trained on the risks and safety measures when working near a boiler, including how to use personal protective equipment, recognize warning signs, and know how to respond in an emergency situation.
In addition, they need to have a clear understanding of how to operate and maintain the boiler correctly, including periodic checks, cleaning and maintenance of components, and knowing how to react in case of an incident. This knowledge and skill not only helps them to work safely but also helps to increase the operational efficiency and extend the life of the boiler. Therefore, investing in the training and development of workers’ skills is an important part of ensuring the safe and effective operation of the boiler.

VII. Occupational Safety Training on Skills for Safe Operation of a Boiler

A. Why do Boiler operators need to be trained in occupational safety?

Occupational safety training for boiler operators is extremely important because it helps to ensure their safety and protect their health during work. Training provides the necessary knowledge and skills to recognize and respond to the risks and dangerous situations that can occur when operating a boiler. This includes recognizing warning signs, knowing how to use personal protective equipment correctly, and having a clear understanding of safety measures and emergency procedures.
In addition, training also helps to improve work performance and reduce the risk of accidents and incidents. When employees are properly trained, they can perform their work more safely and effectively, reducing the risk of accidents and equipment breakdowns. At the same time, investing in occupational safety training also contributes to raising safety awareness and enhancing the safety culture within the organization.

B. Where to get occupational safety training for operating a Boiler?

An Toan Nam Viet is a reputable and high-quality center specializing in occupational safety training in Vietnam today. With occupational safety training sessions held continuously at production workshops, factories, or construction sites across the country (63 provinces in Vietnam).
To ensure the effectiveness of the training, An Toan Nam Viet prepares carefully and meticulously, down to the smallest detail. From preparing tools, equipment, teaching aids to curriculum, materials, sound, and lighting.
The occupational safety training instructors at An Toan Nam Viet are experts with many years of experience in the field. They even have research works identifying hazards in all industries and how to prevent them.
The instructor’s lectures are drawn from practical experience and are conveyed in the most vivid and easy-to-understand way to the workers. These factors help workers feel comfortable during the learning period and absorb the taught knowledge well. Of course, the knowledge conveyed always adheres to Decree 44/2016/ND-CP. From there, they grasp many measures to prevent hazards and how to protect themselves. At the same time, they also apply it most appropriately in their actual work.

VIII. The Significance of Occupational Safety in Operating a Boiler

A. The importance of maintaining occupational safety in operating a Boiler

Maintaining occupational safety in boiler operation is not only a legal obligation but also a decisive factor in the success and sustainability of a business. Occupational safety not only ensures the health and safety of employees but also minimizes the risk of accidents and equipment breakdowns, thereby helping to reduce damage to assets and the company’s reputation.
In addition, maintaining a safe working environment also creates a positive work culture, encouraging focus and attention to the job. Employees feel more secure and confident when they know they are working in a safe environment and are supported by safety measures and work procedures.
Furthermore, adhering to safety regulations and procedures also helps to enhance work efficiency and productivity. Employees working in a safe environment will worry less about the risk of accidents and can focus more on their work, thereby increasing efficiency and work performance.

B. Important safety measures to know before operating a Boiler

Periodic inspection: Perform periodic inspections to ensure that the boiler is operating correctly and there are no hazardous issues.
Use of personal protective equipment: Ensure that all employees are fully equipped with personal protective equipment, including safety glasses, face masks, gloves, and heat-resistant clothing.
Understanding of emergency procedures: Understand and follow emergency procedures in case of an incident, including how to shut down the boiler, how to use a fire extinguisher, and how to perform first aid.
Recognize warning signs: Know how to recognize warning signs of a potential incident, such as strange noises, unpleasant odors, or sudden changes in pressure.
Perform periodic maintenance: Ensure that the boiler is periodically maintained to reduce the risk of incidents and to ensure operational efficiency.

Periodic occupational safety training: Complete the occupational safety training course to be issued an occupational safety card by the safety training center to complete the required documentation for work.