72 Questions
EASY Who verifies that the lockout was performed correctly?
Supervisor or Operations Lock
What do contractors and plant employees record on the lockout sheet?
Their lock number and signature
When is the lockout no longer in effect?
When the car seal is broken
What does the operator record on the lockout sheet after removing the lock?
The lock number and final valve position
What happens to the removed locks?
They are placed back in the lockout box
Who may keep the lockout sheet for future reference?
Safety Officer
What is the primary purpose of the shutdown procedure for a steam boiler?
To test safety interlocks without interrupting production
What should be done to the boiler for several days before shutting it down?
Increase the rate of continuous blowdown and frequency of bottom blowoff
What should be done if the flame is observed to be irregular?
Employ a certified burner service technician to adjust the burner
What should be tested before shutting down the boiler?
All operating and limit controls
What should be done to the boiler steam pressure control before reducing the firing rate?
Put it in manual mode
What should be done after isolating the boiler from the steam header?
Perform a safety valve pop test
What should be done to the boiler control switch after reducing the firing rate to minimum?
Turn it to 'off'
What should be done to the main and pilot manual fuel valves after shutting down the boiler?
Shut, lock, and tag them
What is the first step in shutting down a steam boiler?
Open, lock, and tag the boiler control circuit breaker
When should the boiler non-return valve be closed?
When the boiler stops supplying steam
What should be done to the steam drum vent valve?
It should be opened when the boiler pressure drops to approximately 20 to 35 kPa
What is the purpose of a lockout sheet?
To prepare a lockout procedure for the boiler
What is the purpose of a group lockout?
To apply a lockout to multiple points on a boiler
What should be done to the lockout points on a boiler?
They should be locked and tagged in the shut position
Who is responsible for verifying that all lockout points are locked?
A second qualified operator
What is the purpose of sealing the lockbox with a car seal?
To prevent the lockbox from being opened
Why is it necessary to follow site-specific lockout-tagout procedures?
Because it ensures the safety of the operators and the equipment
What should be done to the boiler feedwater pump if the system has only a single boiler?
It should be turned off and locked out
MEDIUM What should be done to the boiler for maintenance, inspection, or layup?
Increase the rate of continuous blowdown and increase the frequency of bottom blowoff.
Why is it necessary to test safety interlocks during the shutdown procedure?
To identify potential safety issues without interrupting production.
What should be observed for irregularity during the shutdown procedure?
Flame
What should be performed on the boiler steam pressure control before reducing the firing rate?
Put it in manual mode.
What is the next step after isolating the boiler from the steam header?
Perform a safety valve pop test.
What should be done to the main and pilot manual fuel valves after shutting down the boiler?
Shut, lock, and tag them.
What is the purpose of increasing the rate of continuous blowdown and the frequency of bottom blowoff?
To decrease sediment and sludge in the boiler.
What should be adjusted if the flame is observed to be irregular?
The burner.
What is the purpose of recording the lockout in the official Log Book?
To provide a permanent record of the lockout procedure
What happens to the lockbox lock after the work on the boiler is complete?
It is removed by the chief, shift engineer, or delegate
What is the purpose of the lockout sheet?
To record the removal of the locks
Who removes the locks and restores valves and breakers to their previous positions?
A qualified operator
What is the purpose of the car seal?
To indicate that the lockout is no longer in effect
What happens to the removed locks after the lockout is complete?
They are returned to the lockbox
What is the first step in shutting down a steam boiler?
Open, lock, and tag the boiler control circuit breaker.
What happens when the boiler pressure drops to below main steam header pressure?
The boiler non-return valve closes.
Why is it necessary to open the steam drum vent valve?
To prevent a vacuum from forming in the boiler.
What is the purpose of a lockout sheet?
To record the results of all limit tests.
Who is responsible for verifying that all lockout points are locked?
A second qualified operator.
What happens to the key for the lockbox set?
It is placed inside the lockbox.
Why is it necessary to follow site-specific lockout-tagout procedures?
To prevent accidents and ensure safe shutdown.
What is the purpose of sealing the lockbox with a car seal?
To prevent unauthorized access.
What should be done to the boiler feedwater pump if the system has only a single boiler?
Turn it off and lock its breaker.
What is the primary purpose of a group lockout?
To lock out a group of equipment for maintenance.
HARD What is the purpose of increasing the rate of continuous blowdown and the frequency of bottom blowoff several days before shutting down the boiler?
To discharge sediment and sludge that may have accumulated in the boiler
What should be done if the flame is observed to be irregular during the shutdown procedure?
Adjust the burner with a certified technician
What is the purpose of testing all operating and limit controls during the shutdown procedure?
To ensure safety interlocks are functioning properly
What should be done after reducing the firing rate to minimum during the shutdown procedure?
Turn the boiler control switch to 'off'
Why is it necessary to test safety interlocks during the shutdown procedure?
To provide an opportunity without interrupting production
What should be done after isolating the boiler from the steam header during the shutdown procedure?
Perform a safety valve try lever test
What is the purpose of performing a safety valve try lever test during the shutdown procedure?
To ensure the safety valve operates correctly
Why is it necessary to transfer load to other operating boilers during the shutdown procedure?
To maintain stable steam system pressures
What is the primary purpose of the supervisor or operations lock?
To ensure the lockout is performed correctly
What is the purpose of the lockout sheet?
To keep track of the lockout procedure
What happens to the lockout key after the lockout is complete?
It is returned to the lockbox
Who is responsible for removing the supervisory lock from the lockbox?
The chief, shift engineer, or delegate
What is the purpose of the car seal?
To prevent unauthorized access to the lockbox
What is the final step in the lockout procedure?
Returning the lockout key to the lockbox
What is the primary purpose of locking and tagging the boiler control circuit breaker?
To prevent accidental startup of the boiler during maintenance
What is the purpose of opening the non-return valve drain and the steam line vent/drain?
To allow for the safe drainage of the boiler
Who is responsible for verifying that all lockout points are locked and that the boiler is in a zero-energy state?
A second qualified operator
What is the purpose of recording the lockout in the official Log Book?
To provide a record of the lockout procedure
What is the purpose of placing a lockbox lock on a lockout point?
To provide a physical barrier to ensure the boiler is not accidentally started
What is the purpose of sealing the lockbox with a car seal?
To prevent tampering with the lockbox
What is the purpose of isolating the boiler from the main header?
To prevent the boiler from supplying steam to the main header
What is the purpose of closing the boiler non-return valve?
To prevent backflow of steam into the boiler
What is the purpose of locking and tagging the boiler feedwater pump?
To prevent accidental startup of the pump during maintenance
What is the purpose of opening the steam drum vent valve?
To prevent the formation of a vacuum in the boiler
Study Notes
Shutting Down a High-Pressure Steam Boiler
- Increase continuous blowdown rate and frequency of bottom blowoff several days before shutdown to remove sediment and sludge.
- Adjust chemical feed rates to accommodate increased make-up water.
Preparing for Shutdown
- Observe flame for irregularity and employ a certified burner service technician to adjust the burner if necessary.
- Test all operating and limit controls, including:
- Low water cut-off
- Combination feeder/cut-off control or pump control
- High-pressure cut-off
- High and low fuel pressure cut-offs
- Flame scanner/flame failure detection devices
- Combustion air proving switch
- Any other control as specified by the boiler manufacturer
- Perform a safety valve try lever test.
Shutdown Procedure
- Put boiler steam pressure control in manual mode and slowly reduce firing rate, monitoring main steam header pressure to confirm other boilers have taken the load.
- Isolate boiler from steam header and perform a safety valve pop test.
- Turn boiler control switch to "off".
- Shut, lock, and tag main and pilot manual fuel valves.
- Open, lock, and tag boiler control circuit breaker.
Isolating the Boiler
- Close boiler non-return valve (main steam outlet stop valve) when boiler stops supplying steam.
- Isolate boiler from main header, open non-return valve drain and steam line vent/drain, and lock and tag in shut position.
- Close stop valves in boiler feedwater supply line and lock and tag them.
Cooling Down and Lockout
- Let boiler cool down slowly.
- Open steam drum vent valve when boiler pressure drops to approximately 20-35 kPa to prevent vacuum formation.
- Record results of limit tests and time boiler went off-line in log book.
Lockout Procedure
- Follow site-specific lockout-tagout procedures.
- Obtain lockout sheet and lockbox with numbered group lockout locks.
- Place lockbox lock on lockout points, record lock number, and initial lockout point item on lockout sheet.
- Verify all lockout points are locked and electrically operated equipment is de-energized.
- Seal lockbox with car seal and record seal number on lockout sheet.
Removing Lockout
- Workers sign off that their work is complete and remove personal locks from lockbox.
- Chief or shift engineer removes supervisory lock from lockbox.
- Break car seal and remove lockout key from lockbox.
- Qualified operator removes locks, restores valves and breakers to previous positions, and records removal on lockout sheet.
- Record lockbox lockout removal in official log book.
Shutting Down a High-Pressure Steam Boiler
- Increase continuous blowdown rate and frequency of bottom blowoff several days before shutdown to remove sediment and sludge.
- Adjust chemical feed rates to accommodate increased make-up water.
Preparing for Shutdown
- Observe flame for irregularity and employ a certified burner service technician to adjust the burner if necessary.
- Test all operating and limit controls, including:
- Low water cut-off
- Combination feeder/cut-off control or pump control
- High-pressure cut-off
- High and low fuel pressure cut-offs
- Flame scanner/flame failure detection devices
- Combustion air proving switch
- Any other control as specified by the boiler manufacturer
- Perform a safety valve try lever test.
Shutdown Procedure
- Put boiler steam pressure control in manual mode and slowly reduce firing rate, monitoring main steam header pressure to confirm other boilers have taken the load.
- Isolate boiler from steam header and perform a safety valve pop test.
- Turn boiler control switch to "off".
- Shut, lock, and tag main and pilot manual fuel valves.
- Open, lock, and tag boiler control circuit breaker.
Isolating the Boiler
- Close boiler non-return valve (main steam outlet stop valve) when boiler stops supplying steam.
- Isolate boiler from main header, open non-return valve drain and steam line vent/drain, and lock and tag in shut position.
- Close stop valves in boiler feedwater supply line and lock and tag them.
Cooling Down and Lockout
- Let boiler cool down slowly.
- Open steam drum vent valve when boiler pressure drops to approximately 20-35 kPa to prevent vacuum formation.
- Record results of limit tests and time boiler went off-line in log book.
Lockout Procedure
- Follow site-specific lockout-tagout procedures.
- Obtain lockout sheet and lockbox with numbered group lockout locks.
- Place lockbox lock on lockout points, record lock number, and initial lockout point item on lockout sheet.
- Verify all lockout points are locked and electrically operated equipment is de-energized.
- Seal lockbox with car seal and record seal number on lockout sheet.
Removing Lockout
- Workers sign off that their work is complete and remove personal locks from lockbox.
- Chief or shift engineer removes supervisory lock from lockbox.
- Break car seal and remove lockout key from lockbox.
- Qualified operator removes locks, restores valves and breakers to previous positions, and records removal on lockout sheet.
- Record lockbox lockout removal in official log book.
Shutting Down a High-Pressure Steam Boiler
- Increase continuous blowdown rate and frequency of bottom blowoff several days before shutdown to remove sediment and sludge.
- Adjust chemical feed rates to accommodate increased make-up water.
Preparing for Shutdown
- Observe flame for irregularity and employ a certified burner service technician to adjust the burner if necessary.
- Test all operating and limit controls, including:
- Low water cut-off
- Combination feeder/cut-off control or pump control
- High-pressure cut-off
- High and low fuel pressure cut-offs
- Flame scanner/flame failure detection devices
- Combustion air proving switch
- Any other control as specified by the boiler manufacturer
- Perform a safety valve try lever test.
Shutdown Procedure
- Put boiler steam pressure control in manual mode and slowly reduce firing rate, monitoring main steam header pressure to confirm other boilers have taken the load.
- Isolate boiler from steam header and perform a safety valve pop test.
- Turn boiler control switch to "off".
- Shut, lock, and tag main and pilot manual fuel valves.
- Open, lock, and tag boiler control circuit breaker.
Isolating the Boiler
- Close boiler non-return valve (main steam outlet stop valve) when boiler stops supplying steam.
- Isolate boiler from main header, open non-return valve drain and steam line vent/drain, and lock and tag in shut position.
- Close stop valves in boiler feedwater supply line and lock and tag them.
Cooling Down and Lockout
- Let boiler cool down slowly.
- Open steam drum vent valve when boiler pressure drops to approximately 20-35 kPa to prevent vacuum formation.
- Record results of limit tests and time boiler went off-line in log book.
Lockout Procedure
- Follow site-specific lockout-tagout procedures.
- Obtain lockout sheet and lockbox with numbered group lockout locks.
- Place lockbox lock on lockout points, record lock number, and initial lockout point item on lockout sheet.
- Verify all lockout points are locked and electrically operated equipment is de-energized.
- Seal lockbox with car seal and record seal number on lockout sheet.
Removing Lockout
- Workers sign off that their work is complete and remove personal locks from lockbox.
- Chief or shift engineer removes supervisory lock from lockbox.
- Break car seal and remove lockout key from lockbox.
- Qualified operator removes locks, restores valves and breakers to previous positions, and records removal on lockout sheet.
- Record lockbox lockout removal in official log book.
This quiz covers the steps involved in lockout tagout procedures, including placing personal locks, recording lock numbers, and verifying correct lockout.
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