Boilermakers
Boilermakers build and repair boilers, tanks, vessels and stacks in power plants, refineries and mills, working inside confined spaces, at height, and with heavy rigging and welding.
- Industrial
- Construction
Top hazards
- Confined space atmospheres inside boilers, tanks and vessels
- Heat stress inside hot equipment
- Falls from scaffolds and platforms inside boilers
- Heavy rigging and crane lifts
- Welding fumes and arc hazards in enclosed spaces
- Asbestos and other legacy materials in older plants
Key practices
- Follow confined space permits, air testing and attendant rules. See Confined Spaces.
- Isolate and lock out steam, fuel and electrical systems. See Lockout/Tagout.
- Use cool-down periods, ventilation and work/rest cycles for heat.
- Use local exhaust or supplied air when welding inside vessels.
- Follow lift plans for heavy components. See Lift Planning.
Outages and turnarounds
Much boilermaker work happens during plant outages, when a boiler or unit is shut down for repairs on a tight schedule. Crews often work long shifts, seven days a week, with many contractors in the same space. Fatigue, rushing and poor coordination are hazards in themselves. See Refinery & Plant Turnarounds.
Inside a boiler
- Falling slag and ash: clinkers and slag can break loose from tube walls and fall on workers below. Areas must be cleaned and inspected before entry.
- Interior scaffolds: tall scaffolds or rigging platforms inside the furnace must be erected and inspected by competent people.
- Hot, dusty air: fly ash contains silica and metals; respiratory protection is often needed.
- Limited exits: plan rescue before entry. A worker hurt high inside a furnace is very hard to reach.
Long-term health
- Welding fume, including manganese and hexavalent chromium from stainless steel. See Hexavalent Chromium.
- Noise from grinding, air arcing and plant equipment. See Noise.
- Asbestos in older insulation and refractory. See Asbestos.
Before entering a vessel
- Confined space permit issued and posted
- All energy sources and lines isolated, locked out and blanked
- Air tested for oxygen, flammables and toxics, and monitored continuously
- Ventilation running
- Attendant at the entry with a way to call for rescue
- Rescue equipment and plan in place
- Temperature checked and cool-down complete
Standards & references
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