Boilers

Guidelines
Guidelines for the Operation of Hot Water Boilers

GUIDELINES
(Document Reference: PSG 3 Issue 01 Dated 20/12/01)
The Safety Assessment Federation Ltd

Document reference: PSG3 dated 20/12/01

Safety Assessment Federation (SAFed) Guidelines Operation of Hot Water Boilers TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................................................................... 2 1.0 2.0 3.0 4.0 INTRODUCTION.................................................................................................................................................... 3 SAFE OPERATION OF PRESSURISED HOT WATER SYSTEMS .............................................................. 4 CATEGORISATION OF HEATING SYSTEMS................................................................................................ 4 BOILER CONTROLS............................................................................................................................................. 4 Figure 1 Open Vented System Category A ............................................................................................................ 5 Table 1 Recommended and essential boiler controls for an open vented system PSG3 Category A ................. 5 Figure 2 Permanently Connected Gas Cushioned Pressurising Vessel Category B .......................................... 6 Table 2 Recommended and essential boiler controls for a permanently connected gas cushioned pressurising vessel PSG3 Category B............................................................................................................................................ 6 Figure 3 Gas Cushion Closed Vessel with diaphragm or bladder Category C .................................................. 7 Table 3 Recommended and essential boiler controls for a gas cushioned closed vessel PSG3 Category C ..... 7 Figure 4 Pumped Pressure System Category D................................................................................................... 8 Table 4 Recommended and essential boiler controls for a pumped pressure system PSG3 Category D .......... 8 5.0 COMPONENTS ....................................................................................................................................................... 9 5.1 PRESSURE DEVICES ............................................................................................................................................... 9 5.1.1 Pressure Indicator (PI).................................................................................................................................. 9 5.1.2 Safety Valve (PSV) ......................................................................................................................................... 9 5.1.3 High Pressure Limiter (PS+) ........................................................................................................................ 9 5.1.4 Low Pressure Limiter (PS-)........................................................................................................................... 9 5.1.5 Constant Pressure Valve (CPV) .................................................................................................................... 9 5.1.6 Three way valve ............................................................................................................................................. 9 5.2 TEMPERATURE DEVICES ...................................................................................................................................... 9 5.2.1 Temperature Indicator (TI)............................................................................................................................ 9 5.2.2 Return Temperature Indicator (TIR).............................................................................................................. 9 5.2.3 Temperature Controller (TC) ........................................................................................................................ 9 5.2.4 Return Temperature Controller (TCR) ........................................................................................................ 10 5.2.5 Temperature Limiter (TL)............................................................................................................................ 10 5.3 WATER DEVICES ................................................................................................................................................. 10 5.3.1 Low water level limiter (LS) ........................................................................................................................ 10 5.3.2 Water level indicator (LI) ............................................................................................................................ 10 5.3.3 Water level controller (LC) ......................................................................................................................... 10 5.3.4 High water cut-out (LS+) ............................................................................................................................ 10 5.4 COMBUSTION SYSTEMS....................................................................................................................................... 10 5.4.1 Combustion Control System (CCS) ............................................................................................................. 10 5.4.2 Combustion Control System (CCS+) .......................................................................................................... 10 5.4.3 Fire Detection System (FDS)....................................................................................................................... 11 5.4.4 Fuel Leak Detection (FLD) ......................................................................................................................... 11 5.5 ALARMS ............................................................................................................................................................... 11 6.0 6.1 6.2 6.3 6.4 7.0 8.0 MAINTENANCE, REPAIR AND MODIFICATION....................................................................................... 11 GENERAL MAINTENANCE ................................................................................................................................... 11 CONTROLS ........................................................................................................................................................... 11 MODIFICATION & REPAIRS ................................................................................................................................ 12 TESTING RECORDS .............................................................................................................................................. 12 REFERENCES....................................................................................................................................................... 12 ACKNOWLEDGEMENTS .................................................................................................................................. 13

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1.0

INTRODUCTION

These Guidelines are intended to assist competent persons when considering the controls and limiters fitted to existing hot water boiler installations. Separate Guidelines have been produced for shell type steam boilers SAFed Document PSG2 Guidelines for the operation of steam boilers which excluded hot water boilers other than those with an internal steam cushion. These Guidelines supplement PSG2 and provide guidance on the types of controls and limiters necessary to ensure safe operation of fully flooded hot water boiler systems. Other topics covered in PSG2 may be applicable to hot water boilers and should be taken into account where appropriate for example: Definitions Personnel Training Maintenance Keeping of records The Pressure System Safety Regulations 2000 (PSSR) apply to all in service pressure equipment containing a relevant fluid. These regulations may require hot water systems to have a Written Scheme of Examination. A relevant fluid as defined by PSSR requires a vapour pressure greater than 0.5 bar above atmospheric pressure when in equilibrium with the vapour at the actual temperature of the liquid. Hot water should only be considered a relevant fluid at a temperature of 112 C and above. However, steam is a relevant fluid at any pressure. In the case of pressurised hot water systems operating in excess of 100 C and up to 112 C the user should incorporate suitable controls in order to ensure that the system is not liable to contain steam under operating conditions. Note: SAFed strongly recommends that pressurised hot water plant operating in excess of 100 C and less than 112 C is subject to inspection by a competent person. In some systems, including those where hot water is not a relevant fluid, there may be a pressurising or expansion vessel containing air or nitrogen that will require assessment in accordance with the PSSR. Where the product of the pressure in the vessel in bar and the volume of the gas space in litres is 250 bar litres owners or users should ensure that the examination requirements of the PSSR are met. Protective devices for the vessel may be fitted elsewhere in the system. Where hot water systems do not come under the PSSR it is still important that suitable controls and limiters are fitted to ensure safety in operation and these Guidelines also apply to these lower temperature systems. These Guidelines are not intended as a specification for boiler controls in new installations. Such controls should be in accordance with the Pressure Equipment Directive and should comply with the requirements of relevant Harmonised European Standards supporting the directive. Where existing installations do not meet the requirements and recommendations in these Guidelines, a risk assessment should be undertaken to determine whether the controls and limiters fitted provide an acceptable level of safety.

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2.0

SAFE OPERATION OF PRESSURISED HOT WATER SYSTEMS

The user/owner of pressurised hot water systems falling within the scope of the PSSR is required by the regulations to operate and maintain the pressure system in order to ensure safety of personnel. For hot water systems not falling within the scope of the PSSR, it still remains an essential requirement of health and safety legislation for operators to be appropriately trained in the use of boiler controls. Operators should also be fully conversant with the associated protective devices and with all other relevant aspects relating to the safe operation of the system. 3.0 CATEGORISATION OF HEATING SYSTEMS

The four SAFed categories and the description of the heating systems are shown below: PSG3 Category A B C D PSG3 System Description Open vented (with or without combined fill and vent line) Closed pressurised systems with permanently connected gas cushioned pressurising vessels and provision for make-up water. Sealed pressurised systems with separate diaphragm or bladder type pressurising vessels and provision for make-up water Continuously pumped pressurised systems with provision for make-up water.

4.0

BOILER CONTROLS

Recommended and essential boiler controls are identified in the following figures and tables with associated notes. Components are described more fully in section 5.0 R - Recommended E Essential

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System
TC TL PSV TI LS PI

CCS

CCS+

FLD FDS

System
TI R TCR

Figure 1 Open Vented System Category A Table 1 Recommended and essential boiler controls for an open vented system PSG3 Category A COMPONENT Boiler Pressure Boiler Temperature ITEM PSV PI TC TI TL TIR TCR LS CCS CCS+ FDS FLD DEVICE OR LIMITER Pressure Safety Valve Pressure Indicator Temperature Controller Temperature Indicator Temperature Limiter Return Temperature Indicator Return Temperature Controller Minimum Water Level Limiter Combustion Control System High Integrity Combustion Control System Fire Detection System Fuel Leak Detection STATUS R Note 1. R E R E R E Note 2. R E R Note 3. R R

Boiler Water Burner System

*A combined feed and vent pipe arrangement is sometimes used. In the event of steam formation in such a system feed water may be prevented from reaching the boiler. Note 1. Where unintentional vent pipe blockage cannot be precluded e.g. ice formation, then a PSV is essential. Note 2. Only when a minimum return temperature is specified by the manufacturer and a mixing system is incorporated for the flow and return water. Note 3. For extended unmanned operation.

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System

TC TL PSV PS+ PSPI TI LS

Air or N2

PI PSV LS+ LS LC

PS-

CCS

CCS+

FLD

FDS

System
TI R TCR

Figure 2 Permanently Connected Gas Cushioned Pressurising Vessel Category B Table 2 Recommended and essential boiler controls for a permanently connected gas cushioned pressurising vessel PSG3 Category B ITEM DEVICE OR LIMITER STATUS PS+ Maximum Pressure Limiter Below Safety Valve Setting R PSMinimum Pressure Limiter E PSV Pressure Safety Valve E PI Pressure Indicator R Boiler Temperature TC Temperature Controller E TI Temperature Indicator R TL Temperature Limiter E TIR Return Temperature Indicator R TCR Return Temperature Controller E Note 1. Boiler Water LS Minimum Water Level Limiter R Burner System CCS Combustion Control System E CCS+ High Integrity Combustion Control System R Note 2. FDS Fire Detection System R FLD Fuel Leak Detection R Expansion Vessel PSMinimum Pressure Limiter R PSV Pressure Safety Valve E PI Pressure Indicator E LS+ High water cut-out R LS Minimum water level limiter E LC Water level controller R Note 1. Only when a minimum return temperature is specified by the manufacturer and a mixing system is incorporated for the flow and return water. Note 2. For extended unmanned operation. COMPONENT Boiler Pressure

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System

TC TL PSV PS+ PSTI LS PI

CCS

CCS+

FLD

FDS

System
TI R TCR

Figure 3 Gas Cushion Closed Vessel with diaphragm or bladder Category C Table 3 Recommended and essential boiler controls for a gas cushioned closed vessel PSG3 Category C COMPONENT Boiler Pressure ITEM PS+ PSPSV PI TC TI TL TIR TCR LS CCS CCS+ FDS FLD DEVICE OR LIMITER Maximum Pressure Limiter Below Safety Valve Setting Minimum Pressure Limiter Pressure Safety Valve Pressure Indicator Temperature Controller Temperature Indicator Temperature Limiter Return Temperature Indicator Return Temperature Controller Minimum Water Level Limiter Combustion Control System High Integrity Combustion Control System Fire Detection System Fuel Leak Detection STATUS R E E R E R E R E Note 1. R E R Note 2. R R

Boiler Temperature

Boiler Water Burner System

Note 1. Only when a minimum return temperature is specified by the manufacturer and a mixing system is incorporated for the flow and return water. Note 2. For extended unmanned operation.

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System
TC TL PSV PS+ PSTI LS PI LS LI

LC

CPV

CCS

CCS+

FLD

FDS

System
TI R TCR

Figure 4 Pumped Pressure System Category D Table 4 Recommended and essential boiler controls for a pumped pressure system PSG3 Category D COMPONENT Boiler Pressure ITEM PS+ PSPSV PI CPV TC TI TL TIR TCR LS CCS CCS+ FDS FLD LS LC LI DEVICE OR LIMITER Maximum Pressure Limiter Below Safety Valve Setting Minimum Pressure Limiter Pressure Safety Valve Pressure Indicator Constant Pressure Valve Temperature Controller Temperature Indicator Temperature Limiter Return Temperature Indicator Return Temperature Controller Minimum Water Level Limiter Combustion Control System High Integrity Combustion Control System Fire Detection System Fuel Leak Detection Minimum Level Limiter Level Controller Level Indicator STATUS R E E E E E R E R E Note 1. E E R Note 2. R R E R R

Boiler Temperature

Boiler Water Burner System

Expansion Vessel

Note 1. Only when a minimum return temperature is specified by the manufacturer and a mixing system is incorporated for the flow and return water. Note 2. For extended unmanned operation.

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5.0

COMPONENTS

This section details the components listed for each of the categories of hot water heating system. When assessing the suitability of proprietary items it is important that relevant standards and regulations are taken into account. 5.1 Pressure Devices

5.1.1 Pressure Indicator (PI) A suitable pressure indicator is recommended on all pressurised boiler systems so that the operating pressure can be determined. This should be calibrated at appropriate intervals. The range of the gauge should exceed the maximum working pressure by at least 25% and it is useful if the maximum allowable pressure is clearly marked. 5.1.2 Safety Valve (PSV) Each pressurised boiler requires at least one safety valve sized for the rated output of the boiler. On open vented systems a safety valve is essential where the vent could become blocked by freezing or where valves in the system could isolate the vent. There should be no intervening valves between the boiler and its protective safety valves or between the safety valve and its point of discharge to atmosphere. 5.1.3 High Pressure Limiter (PS+) A high pressure limiter is recommended for pressurised boiler systems to lock out the burner at a pressure below the safety valve setting. A suitable margin above normal operating pressure should be incorporated to avoid spurious operation. 5.1.4 Low Pressure Limiter (PS-) A low pressure limiter is essential on pressurised boiler systems to lock out the burner at a pre-determined low pressure which would prevent steam formation at normal operating temperature in any part of the system. The limiter can be fitted to the boiler or be part of the pressurising equipment. 5.1.5 Constant Pressure Valve (CPV) A device to maintain a constant pressure in Category D Systems. Note : If this valve is not self closing on power loss a separate automatic shut off valve should be fitted. 5.1.6 Three way valve If an open vented system utilises a combined vent and feed pipe the only type of valve fitted in the vent/feed line should be a three way valve. This ensures that the boiler is either connected to the open vent or to an open drain connection. 5.2 Temperature Devices

5.2.1 Temperature Indicator (TI) A temperature indicator is recommended on all heating systems so that the operating temperature can be determined. 5.2.2 Return Temperature Indicator (TIR) A return temperature indicator is recommended on all heating systems so that the water return temperature to the boiler can be determined and is essential where the boiler manufacturer has specified a minimum return temperature. 5.2.3 Temperature Controller (TC) A temperature controller is essential on all automatic hot water heating systems to control the firing of the burner and maintain the output temperature within pre-determined limits. The supply of fuel to the burner should be shut off or other action taken to prevent heat input to the boiler at a temperature at least 17 C below the saturated steam temperature corresponding to the pressure at the highest point in the system.
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5.2.4 Return Temperature Controller (TCR) Where the boiler manufacturer has specified a minimum return temperature, and a mixing system is installed to combine flow water with the return water, a return temperature controller is required. If the controller can restrict the flow of water, an independent heating circuit or an overriding thermostat may be necessary to dissipate any residual heat in the boiler. 5.2.5 Temperature Limiter (TL) A temperature limiter, independent of the temperature controller, is essential for all hot water heating systems. The supply of fuel to the burner should be shut off or other action taken to prevent heat input to the boiler at a temperature at least 6 C below the saturated steam temperature corresponding to the pressure at the highest point in the system. For solid fuel fired boilers or other systems where residual heat could cause larger temperature rises this margin should be at least 10 C. 5.3 Water Devices

5.3.1 Low water level limiter (LS) For systems with a separate pressurising vessel in which the water level is controlled a low water level limiter in the pressurising equipment is essential. (BS 2790 requires a low water cut-out and audible alarm and an independent low water limiter for this type of system). It is recommended that all heating systems have a low water limiter fitted to or adjacent to the boiler to prevent firing when the boiler is not fully flooded. 5.3.2 Water level indicator (LI) A water level indicator, normally a gauge glass, is recommended on expansion and pressurising vessels so that the water level can be readily determined. 5.3.3 Water level controller (LC) A water level controller is recommended on expansion and pressurising vessels so that the level is automatically maintained within predetermined limits. 5.3.4 High water cut-out (LS+) A high water protection device is recommended on expansion and pressurising vessels to prevent overfilling or overflow of the vessel. This may be incorporated in the level controller. 5.4 Combustion Systems

5.4.1 Combustion Control System (CCS) A combustion control system is essential on all heating boilers. This should control the firing of the burner in response to the temperature controller and should include the following: Failure to ignite, flame failure or pilot flame failure limiter for oil and gas burners. Forced or induced draught fan proving systems as applicable. Air and flue damper proving systems as applicable.

5.4.2 Combustion Control System (CCS+) High integrity combustion control systems are recommended where extended unmanned operation of heating boilers is envisaged. These high integrity systems should comply with CCS above but should also incorporate self-checking systems monitoring flame detectors and the correct ratios of fuel and air. Unsafe fuel air ratios shall cause lock-out.

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5.4.3 Fire Detection System (FDS) A fire detection system is recommended for all boiler installations but is particularly important for extended unmanned operation. For oil fired boilers this may include a fusible link at the boiler front that automatically shuts off the oil supply. For gas fired boilers this may activate a remote shut off valve outside the boiler house. 5.4.4 Fuel Leak Detection (FLD) In addition to the fire detection system consideration should be given to fitting a fuel leak detection system, e.g. a gas detector system and alarm which shuts off the gas supply for gas fired systems. Double skinned hoses with interspace alarm and shut down for oil fired systems. 5.5 Alarms

Where alarms are required they must be provided at points where persons who are competent to take appropriate action can hear them. Alarms that also give visible warning may, in certain locations, be more acceptable. Remote alarm panels should provide sufficient information to determine which boiler(s) are in operation or alarm condition and, where appropriate, an emergency stop facility. 6.0 6.1 MAINTENANCE, REPAIR AND MODIFICATION General Maintenance

The user/owner shall ensure that the system is properly maintained in good repair and that controls are tested at suitable intervals, so as to prevent danger. The items of plant should be the subject of a suitable planned maintenance programme. Where the manufacturer/supplier has provided recommendations, these should form the basis of the maintenance and/or testing programme. They should be supplemented as appropriate where they are not sufficiently comprehensive to cover the particular installation. In assessing whether the manufacturers/suppliers instructions are sufficient, account should be taken of the complexity of the system, whether they cover the particular installation and whether they reflect the onsite operating conditions. 6.2 Controls

The importance of adequate maintenance on boiler control and alarm systems cannot be over emphasised. Responsibility can be divided between those who own and operate the boiler house and those who maintain it. As this can be different in each case it is imperative that the limits of responsibility of each organisation are clearly defined in writing and understood by all parties. In particular it is important that the following points are noted: Only original or equivalent quality spares should be used. Boiler attendants must ensure that they hand over the boiler to maintenance personnel in a safe condition. On completion of maintenance, all controls and alarms should be checked and verified by the boiler attendant in the presence of the maintenance personnel before the boiler is placed on line.

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6.3

Modification & Repairs

It may be necessary to carry out modifications or repairs to the boiler and burner control and alarm systems. Significant modifications and repairs that affect integrity and/or safety of the system, its controls, and software, should be properly considered. The competent person should be kept fully informed of such modifications and repairs where PSSRs apply. 6.4 Testing Records

It is strongly recommended that the testing of controls and limiters is recorded for future reference. A dedicated logbook suitably prepared to record date and outcome of each test is considered to be the best way of maintaining this type of information. The logbook should be maintained in the boiler house. 7.0 REFERENCES

The following are applicable at the time of preparation of this Guidance: a) SAFed Document PSG2 Guidelines for the operation of steam boilers b) The Pressure Systems Safety Regulations 2000 (SI 2000 No 128) c) Pressure Systems and Transportable Gas Containers Rules (Northern Ireland) 1991. No 471 d) Health and Safety at Work etc. Act 1974 e) BS 2486: 1997 Recommendations for treatment of water for land boilers f) BS EN 676: 1997 Automatic Forced Draught Burners for Gaseous Fuels g) BS EN 746: 1997 Part 2 safety requirements for Combustion and Fuel Handling Systems h) BS EN 298: 1994 Automatic Gas burners control systems for gas burners and gas burning appliances with or without fans i) BS 799: Part 4: 1991 Specifications for atomising burners (other than monobloc type) together with associated equipment for single burner & multiburner installations j) DIN VDE 0116 Testing of burner management systems k) DIN 4787 Part 2. Type testing of Flame monitors l) DIN 4788 Part 3. Type testing of Flame monitors

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8.0

ACKNOWLEDGEMENTS

SAFed wishes to express its gratitude to the following Organisations and Companies who helped directly or indirectly in the compilation of this Guidance: Allianz Cornhill Engineering Royal & SunAlliance Zurich Engineering Plant Safety Ltd HSB Haughton Engineering Insurance Services Ltd SGS UK Ltd, Industrial Division TV UK Ltd Hibernian Insurance Co Ltd

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