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HEAT TRANSFER A GUIDE TO BG13
In this article, Fulton managing director Carl Knight delves into the
importance of
BG13 and the insights it provides into how to ensure the safe operation of
electric powered steam boilers
intended to assist the managers, designers, operators, maintenance personnel and Competent Persons (CP) of new and existing steam boiler systems. Developed and written by the Combustion Engineering Association (CEA) and in consultation with other stakeholders – like Fulton – within the steam boiler industry, it serves as a vital resource to those named and addresses key issues including design, installation, safe operation, maintenance requirements, and compliance with legal standards.
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The document covers various dangers and challenges including loss of feed water, over- pressure, overheating, electrical safety, and water treatment. Electric boilers – classified as small, medium, or large – encompass two main types: electric boilers and electrode boilers. Electric boilers utilise fully immersed heating elements, while electrode boilers employ conducting probes or electrodes to directly heat the water.
BG13 applies to industrial and commercial electrically powered steam boiler plants with a working pressure up to 32 bar gauge. It excludes steam boilers exceeding 37 MW nett rated thermal input or above 32 bar gauge working pressure, as well as coffee boilers, jet type electrode boilers, and hot water boilers. Nevertheless, the principles outlined in BG13 can still be applied where suitable and applicable, even to excluded boiler types. Proper design and installation are fundamental to the safe operation of electric steam boilers. BG13 outlines design considerations such as sizing the boiler to meet the specific requirements of the application, ensuring adequate ventilation, and implementing appropriate safety features such as pressure relief valves and automatic shutdown systems. To guarantee compliance with BG13
uidance for the Safe Operation of Electrically Powered Steam Boilers (Ref: BG13) is a guidance document
standards, installation should be undertaken by qualified professionals and follow manufacturer guidelines and relevant regulations.
This section outlines operational requirements and routine checks for electric boiler systems. Employers must conduct site- specific risk assessments to determine appropriate controls, supervision levels, and maintenance. Before use, boilers must be examined by a competent person and subsequently tested according to a Written Scheme of Examination (WSE).
Overall, BG13 provides a comprehensive framework for ensuring the optimal performance and safety of electric steam boilers
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Boiler instructions should cover safe operation, daily checks, start-up procedures, safe work practices, and notification of significant operational changes. System re- starts following lock-out require a suitably experienced operator to avoid potential risks. Routine testing of controls, limiters, and water quality is crucial for safe and efficient operation. Testing frequency should be based on risk assessment, manufacturer's instructions, and operational requirements. Records of tests and maintenance activities must be maintained for audit purposes. Water level controls need specific testing, with results logged and corrective actions taken as necessary. Feed water and boiler water checks, including chemical dosing and quality assessments, should be conducted regularly.
Special consideration must be given to water treatment for standby and unused
14 JULY/AUGUST 2024 | PROCESS & CONTROL ” boilers to
prevent scale build-up and ensure system integrity.
The user/owner must appoint competent individuals responsible for daily boiler operation, with competence entailing relevant education, training, and experience. Operators must be capable of recognising the limits of their expertise and seeking assistance when necessary and their duties are determined by site-specific risk assessments. Employers have general duties to provide safe workplaces and adequate staff training under the Health & Safety at Work Act 1974, MHSWR, and PUWER. These responsibilities cannot be delegated to employees or third parties. Qualified electricians or electrical engineers must manage electrical issues associated with boilers, ensuring electrical safety, compliance with regulations, and implementing safety measures. Individuals monitoring boiler alarms must be adequately trained to respond appropriately to alarm conditions, ensuring safety before seeking assistance. Access during emergencies should be restricted to trained personnel. Maintenance personnel require sufficient knowledge and training to carry out their duties safely, performing tasks only for which they are trained and competent. User/owners hiring subcontractors for specialised tasks must ensure their competency, oversee their work, and ensure compliance with legal requirements and safety standards. Manning and supervision levels are determined by detailed risk assessments, considering factors like automation, location, water quality, and operational scenarios. Electric boilers require a competent operator present during start-up and lockout. Advanced automation may still necessitate full-time supervision for steam security or
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