Playing it safe 07 December 2011

The October 2011 arrival of new guidance for the safe operation of steam and hot water boilers gives boiler operators and managers up-to-date advice, and recognised training is a key focus. Brian Wall reports

Guidance on the safe operation of boilers finally caught up with changing technology with the publication on 25 October this year of 'Guidance on the Safe Operation of Boilers' (BG01). Drafted by CEA (Combustion Engineering Association), SAFed (Safety Assessment Federation) and the HSE, BG01 runs in parallel with the latter's 'Safe management of industrial steam and hot water boilers' (INDG436), which was published on the same day.

The arrival of BG01 will be more significant than INDG436 for most engineers and technicians working day-to-day with boilers, because it gives very specific advice about how to achieve the aims laid out in the HSE document.

"INDG436 does not give much guidance for a person working at the sharp end," states David Arnold, acting director of the CEA. "It tells you what the regulators want, but not how to do it. Over the past three years, SAFed and the CEA have drawn up a more detailed guide to tell boiler operators and managers how to achieve those safety standards. HSE was also involved and fully endorses BG01" he adds.

Farewell PM5
BG01 replaces the old PM5 and PSG2 guidance notes from the HSE and SAFed respectively. Rapidly evolving control technology was one of the big drivers for changing the guidance. "PM5 didn't take account of the increasing computerisation of boiler controls, so it had to be revised," states Arnold. "Remote access is another good example of how technology has moved on. These days you could, in theory, have someone with a laptop in Welwyn Garden City controlling a boiler plant in Manchester. That would have been totally unthinkable when PM5 was drawn up."

The updated advice has been a long time coming and the process has not always gone smoothly. Ineed, an inability to agree led several years ago to SAFed unilaterally publishing its own PSG2 guidelines. But it's here now. So what does the new regime mean for people working with steam and hot water boilers?

In terms of equipment, it's the wider range of control options that probably marks the biggest change. And as far as making sure that technicians are up to scratch, it's the minimum recommended qualifications that come under particular scrutiny. There are a number of boiler- and steam-related courses available at various levels, but BG01 recommends that operators and managers achieve the national industry standards through the following qualifications:
Certified Industrial Boiler Operator (CertIBO) for operators.
Diploma in Boiler Plant Operation Management (DipBOM) for managers.

Both of these qualifications are part of the Boiler Operation Accreditation Scheme (BOAS). "BOAS itself is not new," concedes Arnold. "Over 1,000 candidates have already completed BOAS training with Spirax Sarco and other providers."

That is reassuring, and Chris Coleman, training and development engineer at Spirax Sarco (a member of the committee that drafted BG01) adds that BOAS training is not especially onerous for experienced engineers. "We offer a four-day BOAS-accredited course for boiler operators and managers that provides the necessary qualifications to cover participants for five years, after which a refresher is required."

Why bother?
"Safety is obviously the main driver, but proper training can also save money for boiler owners and operators," explains Coleman. "Properly operated steam boilers provide a safe and efficient way of moving energy around. Complying with the new advice will not only improve the safety of boiler operations. Knowing the best way to operate and maintain a steam system is the key to improving efficiency, boosting productivity and reducing costs. Any initial outlay will soon be repaid in a typical steam installation," he asserts.

Incidentally, even though BG01 is guidance, rather than a legal requirement, operating a boiler plant in line with the latest advice is an obvious way to demonstrate to regulators and insurers that you're committed to best practice and have appropriately trained personnel. "This guidance is not legally binding, but if you end up in court and the judge asks if you followed the best available advice and you didn't, it doesn't look good," warns Arnold.

He accepts that BG01 hasn't come up in court yet, simply because it is new. However, he reminds plant engineers that guidance around safety-related best practice can progressively be transformed into a de facto legal requirement, once case law has been established.

Insurers are also keen for steam system operators to demonstrate an appropriate level of care, and BG01 is now the best way to deliver it. Ultimately, however, the biggest reward is a safer working environment.

Brian Tinham

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