BOILRC/O/G-A Boiler (Coal, Oil, and Gas) - Annual

                                          Under 120 MBTU Man Hours 2.5
                                            120-300 MBTU Man Hours 5
                                            300-500 MBTU Man Hours 8
                                            500-700 MBTU Man Hours 24
                                           700-1000 MBTU Man Hours 32
                                          Over 1000 MBTU Man Hours 40
Special Instructions:

1.  Review manufacturer's instructions and ASME Boiler and Pressure Vessel Codes
    for boilers.
2.  Review the Procedure for "Selection, Care and Use of
    Respiratory Protection."
3.  Review the Procedure for "Controlling Hazardous Energy
4.  Deenergize, tag, and lock out circuits.
5.  Close and tag all hand or motorized valves required to isolate the boiler.
    Chain and lock all valves that are closed for safety.  These valves shall not
    be unlocked and reopened unless authorized by the originator of the work
    authorization.  Enter this information in the boiler log and sign.
6.  Wear appropriate respirator, goggles, and gloves while in contact with
    hazardous materials.  Contact the Safety and Environmental Management
    Division/Branch if you have questions.
7.  If materials to be worked on are known or suspected to contain asbestos,
    check the building's asbestos management plan to see if they have been tested
    for asbestos.  If they are suspect but have not been tested, have them
    tested.  Manage asbestos in accordance with the plan.
8.  Account for all tools and materials before closing boiler.

Items to Check & Initial Completion:

1. ___ Apply hydrostatic test of safety pop-off valve (1.5 times operating
       pressure, safety valve gauged).
2. ___ Drain boiler, tag valves and controls.  NEVER attempt to remove a manhole
       or handhole cover with out first properly venting the water or steam side
       of a boiler to the atmosphere. Prior to opening or entering a boiler it
       must be at atmospheric pressure.  To protect the boiler from unnecessary
       stresses the boiler water temperature should be allowed to reach the
       boiler room temperature before draining the boiler.
3. ___ Brush all tubes clean of scale.
4. ___ Brush plate surfaces clean, use vacuum cleaner.
5. ___ Clean breaching, ducts, fireboxes, or main fire tube, and
       flue passages.
6. ___ Check and replace worn or damaged insulation.  Repair the damage and
       remove the debris.  If the insulation contains asbestos, follow the
       asbestos management plan for isolation, notification, work practice, and
       waste disposal.
7. ___ Check refractory and brick work; if damaged notify supervisor and enter
       this data in boiler log.
8. ___ When the boiler has cooled to the ambient boiler room temperature, wash
       out mud legs, and flush boiler
9. ___ Refill boiler with water and chemicals if boiler is to be put back in
       service or if wet-lay-ups are to be employed.
10.___ Determine if there is ample provision for expansion between
       the sections.
11.___ Check for excessive rust build-up between sections (cast iron  type).
12.___ Examine all steam and water line to controls to determine
       that they are clear of scale and arranged to insure proper control
13.___ Clean stems and shafts, and tighten packing nuts on valves
       and pumps.
14.___ Flush fuel oil strainer baskets and oil solenoid valve seats.
15.___ Dismantle low water fuel cut offs and water feeders to insure  freedom
       from obstructions and proper functioning of the working parts.  Always
       replace old gaskets before reassembling.
16.___ Inspect connecting lines to boiler for accumulations of mud,
       scale, etc., and clean as needed.
17.___ Examine all visible wiring for brittle or worn insulation,
       and make sure electrical contacts are clean and functioning  properly.
18.___ On electrical type detection devices, replace vacuum tubes
       annually, and replace defective solid state devices.
19.___ Replace fusible plugs, if applicable.

Tools & Materials:

1.  Standard Tool kit.
    Plus Pipe wrenches to 24"
         Tubing cutters
         Flaring tool
         Small acetylene outfit
         Packing tool kit and packing
         3/4" socket set
         Crescent wrenches to 14"
2.  Scrapers, wire brush, cleaning materials.  Consult the Material Safety Data
    Sheets (MSDS) for hazardous ingredients and proper personal protective
    equipment (PPE).
3.  Combustion testing equipment
4.  Hydrostatic pump and safety valve gag
5.  Respirator
6.  Safety goggles
7.  Safety signs
8.  Suitable chain and locks for securing isolation valves.
9.  Boiler chemicals as directed by a competent water treatment company. Consult
    the MSDS for hazardous ingredients and proper PPE.
10. Vacuum cleaner wet/dry type.

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