Annex B To Loughborough University Facilities Management Health and Safety Policy

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1 Annex B To Loughborough University Facilities Management Health and Safety Policy Pressure Systems Safety Procedures 1. General a. The following aspects relating to safety are covered in these procedures:- Asset Development Manager - Engineering and their Nominated Deputy Mechanical Services Supervisor Display of information (relating to safe operation) Safety Regulations (operations) Reporting of Accidents and Dangerous Occurrences Permits to Work Working in confined spaces Work on Live high temperature hot water and medium temperature hot water systems Procedures b. The procedures contained within this document are MANDATORY and are to be complied with by all directly employed by FM staff and their contractors. c. Compliance with these procedures should ensure compliance with Statutory Requirements, but where conflict or omission arises, Statutory Requirements are to be followed, and the matter referred to the Project Manager and Departmental Health and Safety Manager. 2 Definitions a. Relevant fluid (as applicable within this guide) Steam Any fluid that would have a vapour pressure greater than 0.5 bar above atmospheric pressure when in equilibrium with its vapour at either the actual temperature of the liquid or 17.5 degrees Celsius. Examples relevant to FM would be Medium Pressure and High Pressure Hot Water Systems and Compressed Air. Oct 09 Page 1 of 13

2 b. Pressure System Within the requirements of this guideline, the term 'Pressure System' means any system comprising one or more pressure vessels of rigid construction, any associated pipework and protective devices which contain or is liable to contain a relevant fluid, the pipework to which a transportable pressure receptacle is, or is intended to be connected but does not include a transportable pressure receptacle. Reference to systems sizes and capacity is as indicated in 'The Safe Pressure Systems Regulations 2000'. (NB A rule of thumb of the product of the Pressure and Volume of the total system being less than 250 bar-litres will afford some guidance as to whether or not the regulations apply. However the regulations themselves should be referred to if any doubt exists. No relief whatsoever from the requirements to provide adequate and suitable instructions for the safe operation of the system and the action to be taken in an emergency is afforded under the 2000 Regulations. c. Asset Development Manager - Engineering (ADME). The Asset Development Manager - Engineering, of Loughborough University Facilities Management. d. Nominated Deputy A person authorised and nominated in writing by the Asset Development Manager - Engineering from time to time as competent for the purposes of undertaking such duties as prescribed at the time. (As exemplified by the Mechanical Services Supervisor of Loughborough University Facilities Management.) e. Mechanical Services Supervisor The Supervisor appointed by the Asset Development Manager - Engineering as being experienced in Boilers, Pressure Systems and Pressurised Systems, and suitably conversant with the Loughborough University procedures and installations. f. A Permit to work (Pressure Systems) An example is shown at Appendix 1 which, when completed, becomes an accountable document Oct 09 Page 2 of 13

3 g. A Competent Person (Pressure Systems) A competent individual person (other than an employee), or a competent body of persons corporate or incorporate. More commonly indicated as: A Suitably qualified Engineer Surveyor, normally of an Insurance Company, employed by the Insurance Company on behalf of Loughborough University for the purposes of carrying out examinations on Pressure Systems. h. Examination The careful and critical scrutiny of a pressure system or part of a pressure system in or out of service as appropriate, using suitable techniques, including testing where appropriate, to assess: - i. Its actual condition, and ii. Whether, for the period up to the next examination, it will not cause danger when used if normal maintenance is carried out, and for this purpose' normal maintenance' means such maintenance as it is reasonable to expect the user or owner to ensure is carried out independently of any advice from the Competent Person making the examination. i. A Thorough Examination An examination carried out by a Competent Person (Pressure Systems) of a Boiler in the cold and empty condition, or a pressure vessel (when open to atmosphere) as required and described within the Pressure Systems Written Scheme of Examination. j. A Working Examination An examination carried out by a Competent Person (Pressure Systems) on the first occasion (following a thorough Examination), that normal working pressures and temperatures are attained as described within the Pressure Systems Written Scheme of Examination. k. A Report of an Examination A report issued by a Competent Person (Pressure Systems) on the relevant form, as prescribed by the Health and Safety at Work Act (1974), or where the item is not subject to the Act by definition, on the Insurance Company s or Contractor s approved form. Oct 09 Page 3 of 13

4 l. Certificate of Test A certificate, when completed by a Competent Person (Pressure Systems) or by the original boiler manufacturer specifying the Maximum Permissible Working Pressure of a boiler or the Safe Working Pressure of a component part of the Pressure System or other Pressure Vessel. A Certificate of Test shall identify the plant to which it refers and state the test(s) on which it is based. m. Maximum Allowable Pressure (of a Boiler) The Pressure specified on the Certificate of the Test, or in the most recent Report of an Examination of the item of plant. n. A Steam Boiler Any closed vessel in which for any purpose steam is generated under pressure greater than atmospheric pressure. Any reference to a steam Boiler shall apply to the mountings (including any fittings and attachments). o. A Steam Receiver Any vessel or apparatus (other than a Boiler, container, pipe coil or part of a prime mover) used for containing steam under pressure. A calorifier in which the primary medium is MTHW is to be treated as a steam receiver for the purposes of these procedures. p. A Steam Container Any vessel (other than a steam pipe or coil) constructed with a permanent outlet to the atmosphere, or to a space where the pressure does not exceed atmospheric pressure, and through which steam is passed at atmospheric pressure, or at approximately that pressure for the purpose of heating, boiling, drying, evaporating, humidifying or similar purposes. q. An high temperature hot water (HTHW) or medium temperature hot water (MTHW) Boiler (as appropriate for Loughborough University Facilities Management). Any vessel in which water is heated to a temperature higher than 95 C and which is pressurised by air, nitrogen or other gas, or by a static head or continuous pumping. r. A low temperature hot water (LTHW) Boiler A boiler, which operates at a temperature below 95 C on a non-pressurised system. Oct 09 Page 4 of 13

5 s. Pressure Vessel Any Vessel, other than a steam boiler in which steam, air or other relevant fluid is contained under pressure. The pipework with its protective devices to which a transportable pressure receptacle is, or is intended to be, connected; or A pipeline and its protective devices, which contains or is liable to contain a relevant fluid, but does not include a transportable gas container. t. Safe Operating Limits The operating limits, incorporating a suitable margin of safety, beyond which failure is liable to occur. The Safe Working Pressure is specified on the certificate of test or in the most recent Report of an Examination of the pressure vessel. u. An Air Receiver Any vessel (other than a pipe coil, accessory, fitting, or part of a compressor) for containing compressed air and connected with an air compressing plant; or Any fixed vessel for containing compressed air or compressed exhaust gases and used for the purpose of starting an internal combustion engine; or Any fixed or portable vessel (not being part of a spraying pistol) used for the purposes of spraying by means of compressed air, any paint, varnish, lacquer or similar material or, Any vessel in which oil is stored and from which it is forced by compressed air; or Any fixed vessel which contains or can contain any gas above atmospheric pressure or, Any Vacuum receiver v. Plant Any individual item of equipment such as a boiler or a pressure vessel. w. A Confined Space (as applicable under this guidance procedure) The water steam or combustion space of a boiler or any pressure vessel, chamber, pipe, pit, vat or tank. Oct 09 Page 5 of 13

6 3. Examination, Testing and Reporting Asset Development manager Engineering (ADME) Duties a. The Asset Development Manager - Engineering is to maintain a Plant Record Folder/Binder, to be known as the Written Scheme of Examination for each pressure system, containing every item of plant that is subject to examination, testing and reporting by a Competent Person (Pressure Systems). Such records are to be held centrally within the FM Services Offices with scanned (pdf files or equivalent saved in the Health and Safety Pressure Systems Schemes of Examination folder on the shared drive. b. Where a Project Manager is accepting a building or any part thereof which incorporates a pressure system or which is served from an existing pressure system, the Project Manager must ensure that the Asset Development Manager Services accepts the system on behalf of the University and that the ADMS is the signatory on any associated pressure systems certification. c. It shall be the duty of the Loughborough University Project Manager or equivalent Officer-in-charge of new works to ensure that a suitable Written Scheme of Examination is made available on completion of the works, prior to any pressure system being brought into use. d. Each folder should contain copies of the documents listed below i. A brief description of the system. ii. iii. iv. A Certificate of test, together with any documents arising from the examination(s) made during the construction of the plant, A detail sheet containing the relevant information on the particular item of plant, including a list of all incorporated plant, safety valves, pressure gauges, thermometers, high and low pressure safety devices, bursting discs and other safety controls. Such should carry individual identifying marks, cross-referenced to the actual items installed on site. (See also Appendixes 2 and 3). Every current Report of an Examination by a Competent Person (Pressure Systems) together with a record of action taken to comply with any recommendations made therein; NB. Such reports may not exist on installations less than one year old, but may be relevant where projects extend beyond and plant has been in operation for 12 months or more. v. A record of any examination, test or modification carried out on any part of the plant. Oct 09 Page 6 of 13

7 vi. vii. viii. ix. Particulars of any defect found which affects the safe working of the plant, and a record of the steps taken to report its occurrence to the Competent Person (Pressure Systems) and to remedy the defect. A copy of any defect or failure report, or relevant Tradesman's or Contractors' call out report for pressure relevant items. A schematic drawing or diagram specific to the relevant pressure system. (It is suggested that 'As Installed' drawings containing information other than that relating to the relevant pressure system will not be suitable.) Copies of Written Schemes of Examination are available for perusal on request. e. The Mechanical Services Supervisor is to assist the Asset Development Manager - Engineering in ensuring that Pressure Systems are adequately prepared for thorough Examination in readiness for the Competent Person (Pressure Systems) by the due date. This will include providing attendance, assistance and facilities at the examination for the drilling of plates, for lifting, for hydraulic testing and for ensuring hand lamps or electric torches are available as required. It should be noted that external contractors might be utilised to carry out this work at the discretion of the Asset Development Manager - Engineering. f. At supplementary examinations, only site attendance for operating the boilers or pressure vessel to the requirements of the Competent Person (Pressure Systems) will be needed. The above may be carried out in part or full by contract or direct labour at the discretion of the Asset Development Manager - Engineering. 4. Plant to be examined and reported on by a Competent Person See Appendix 2 a. It should be noted that this includes, but is not necessarily limited to those items of plant, Pressure Systems and boilers subject to examination, testing and reporting by a Competent Person, under the Health and Safety at Work etc. Act 1974, the Pressure Systems Regulations or by Loughborough University requirements. b. Pressure Systems and/or items included in the list are not to be taken into use or continue to be used unless the Asset Development Manager - Engineering has possession of, (or a certified copy of) the Certificate of Test and/or a Current report of a Thorough Examination or a Supplementary Examination as appropriate. See requirement for a Written Scheme of Examination. 5. New Installations Oct 09 Page 7 of 13

8 a. The Supervising Officer, or the Facilities Management Project Manager in the case of installations overseen by consultants, shall arrange for the Competent Person (Pressure Systems) to undertake as necessary:- i. Approval of and attendance on manufacturers' tests at works as applicable, and the issue of a Certificate(s) of Test as appropriate. ii. iii. Initial examination and test, or the witnessing of such after installation completion and commissioning with relevant certification. The provision of a 'Written Scheme of Examination', consisting sufficient information concerning the design, construction, examination, operation and maintenance as may be foresee ably needed in order that the Pressure Regulations may be accorded with. Examples of such schemes are available for perusal in Facilities Management maintenance section. NB This requirement is specific to Pressure Systems and in addition to any other documentation supplied under any contract. 6. Examining, Testing and Reporting (continued) a. Each of the items covered by the schedule in Appendix 2 is to have a Thorough Examination as required in the Written Scheme of Examination. On the first occasion when the boiler is operated after original certification, or as soon as practicable thereafter, the boiler shall be subjected to a supplementary examination. b. All brickwork, baffles, and coverings are to be removed to the extent necessary to expose headers, seams of shells and drums:- - At least once every 4 years for all relevant boilers. - At the discretion of the Competent Person (Pressure Systems). 7. Pressure Systems Each of the Pressure Systems covered in the schedule at Appendix 2 is to have a 'Thorough Examination' internally and externally as far as practicable, and a Supplementary Examination under normal working conditions at the maximum intervals indicated in the Written Scheme of Examination. 8. Other Examinations The Competent Person (Pressure Systems) shall be employed when any of the following services is required: Examination of Defect(s) Examination, test and supervision during and after repair or modification Oct 09 Page 8 of 13

9 Examination and test on change of location. 9. Preparation of Plant for Examination a. Boilers Each Boiler is to be isolated, cooled down and emptied; The covers are to be removed from all manholes and hand-holes The waterside surfaces are to be thoroughly cleaned, and any scale and surface deposits removed. This operation to be carried out immediately the boiler is opened up. Should deposits be allowed to dry and harden, power washing is to be employed or chemical cleaning and subsequent passivation. Any such cleaning only to be carried out under the guidance of Loughborough University approved water treatment specialists. The fireside surfaces are to be accessed and thoroughly cleaned, and any soot or other deposits totally removed, to the satisfaction of the Asset Development Manager - Engineering/Nominated Deputy, Mechanical Services Supervisor, and the Competent Person (Pressure Systems). The fireside surfaces should be cleaned as quickly as possible after sheet down, following adequate cooling, and the gas spaces kept well ventilated. Mechanical cleaning aids are to be used as required. See references to 'Confined Spaces'. Oil or Gas burners are to be disconnected and hinged, or removed from the front plate where necessary to gain access to the furnace and suitably protected and stored. During four year testing and examination, any furnace, fire bridges, furnace protective brickwork or linings, and external coverings are to be removed sufficiently to facilitate hydraulic and non-destructive testing of the boiler. At all thorough examinations, all boiler mountings e.g. the safety valve, stop valve, stop valve flow and return valves, and other connections to the boiler shell or drum are to be opened up and dismantled. All such valve spindles are to be withdrawn from their covers. Details of any other requirements should be obtained from the Competent Person prior to presentation for Thorough Examination. Following successful inspection, boilers are to be rebuilt, refilled and brought back onto line and subsequently have their operating efficiencies and any safety provision proven. This to include any mechanical and electrical protection. All tests carried out shall be suitably certified and together with any gas certification presented to the Asset Development Manager - Engineering or Nominated Deputy. b. Air Receivers Oct 09 Page 9 of 13

10 Receivers of welded construction provided with a means of examining the internal surfaces. Isolate from air supply, release pressure and drain accumulation of oil and or water. Open up and dismantle mountings (as for Boilers) External surfaces are to be thoroughly cleaned. External underside parts to be accessed if required by Competent Person (Pressure Systems). Accessible internal surfaces are to be thoroughly cleaned. c. Receivers of Solid Drawn Construction without a means for thoroughly examining the internal surfaces. Isolate from air supply, release air pressure, and drain oil and water. Open up and dismantle mountings (as for boilers) Thoroughly clean external surfaces Provide attendance for hydraulic test as required by the Competent Person (Pressure Systems). d. Economisers, Superheaters, Autoclaves, Steam Tube Ovens, Steam Receivers, Oil Fuel Heaters and Kitchen and relevant refrigeration equipment. Following testing, the equipment shall be rebuilt and have any associated mechanical and electrical safety provision tested and certified before being brought back into service. 10. Safety in the Operation and Maintenance of Pressure Systems Safety regulations (operations). The Mechanical Services Supervisor or their Nominated Deputy is responsible for:- a. Ensuring that the precautions detailed in Appendix 3 are always taken when lighting up and bringing into service a steam or hot water boiler. b. Ensuring that a suitable and sufficient risk assessment has been undertaken before any work is carried out on the system and reassessing the risk as appropriate. c. In the event of either a defect arising which affects the safe working of the plant, or receiving an adverse report from the Competent Person (Pressure Systems), carrying out the following. Oct 09 Page 10 of 13

11 Withdrawing the plant from use. Notifying, via their line manager, the Competent Person (Pressure Systems). Making a written report, a copy of which is to be held in the Plant Record folder/binder (Log book).. Restoring the plant to use the following repair, after receipt from the Competent Person (Pressure Systems) of a satisfactory report of an examination if appropriate. d. Assistance in the allocation and maintenance of a record of plant, listing:- Location, Plant description, manufacturers number(s), local number(s). e. Displaying, in a clearly visible position:- The Maximum Permissible Working Pressure, or the Safe Working Pressure of a boiler or pressure vessel respectively. The local number(s) of the plant proceeded by an abbreviation of the name of the establishment in conjunction with the Asset Development Manager - Engineering. Marking the Maximum Permissible Working Pressure, or the Safe Working Pressure on each pressure gauge in RED. In conjunction with the Asset Development Manager - Engineering Ensuring that Schematic Drawings of plant layout and systems are displayed in Boilerhouses or Plant Rooms as appropriate are up to date. Ensuring that all valves installed in Boilerhouses and on systems are clearly identified. Ensuring that inadequacies of access to plant and equipment in Boilerhouses and Plantrooms are brought to the attention of Asset Development Manager - Engineering. Ensuring that all controls and alarms affecting the safe operations of plant are correctly adjusted and fully functional at all times that the plant is in use, and that following any adjustment or repair a full functional test is carried out before the plant is restored to normal operation. 11. Action In Emergency a. The Mechanical Services Supervisor, in conjunction with the Maintenance Manager is to ensure that all staff in their charge who are likely to work with Oct 09 Page 11 of 13

12 pressure systems in an emergency situation are fully conversant with Boilerhouses layouts, and with the correct emergency procedures. b. See Appendix 4 (Emergency Procedures Hot Water Boilers) 12. Boiler Explosions, Accidents, and Dangerous Occurrences Any such occurrences to be reported immediately, to the Asset Development Manager - Engineering and Departmental Safety Officer (DSO). 13. Display Of Notices The notices shown at Appendix 3 and 4 shall be displayed in each relevant Boilerhouse. 14. Permit To Work (Pressure Systems) a. This code gives details of the procedure to be adopted for issue by, return to and cancellation by the FM Mechanical Services Supervisor or their Nominated Deputy of a Permit to Work. (Pressure Systems). b. A Permit to Work (Pressure Systems) is to be withdrawn if the conditions under which it was issued change, if FM staff or a contractor disregard any Safety Regulations, or if there is a failure of the safety equipment and the Asset Development Manager - Engineering/Nominated Deputy informed immediately. c. The Maintenance Manager, with the help of the Mechanical Services Supervisor shall maintain a folder for each Total System, in which the copies of Permits to Work (Pressure Systems) and cancelled declarations shall be retained. d. Procedures i. The Mechanical Services Supervisor in conjunction with the Maintenance Manager is responsible for co-ordinating all mechanical and electrical work related to boilers, Pressure Systems, and other relevant systems under their charge, and is to ensure liaison with contractors or Project Managers where employed to work on systems as required by the Asset Development Manager - Engineering. ii. iii. Before issuing a Permit to Work, the Mechanical Services Supervisor or their Nominated Deputy, having personally isolated, made safe and affixed suitable padlocks and caution notices, shall demonstrate that the system is safe to work on and is to bring to the notice of the person in charge of the proposed work any requirement for an attendant, the requirement for protective clothing, safety helmets, etc as appropriate. No person shall enter any confined space or carry out work on a Pressure System or system associated with the above unless they are in possession of a Permit to Work (Pressure Systems), a Permit to Work (Confined Oct 09 Page 12 of 13

13 Spaces) if applicable and an approved Risk Assessment has been carried out. iv. Before issuing a Permit to Work (Pressure Systems) and/or a Permit to Work (Confined Spaces) the Mechanical Services Supervisor or their Nominated Deputy shall satisfy themselves that the following precautions have been taken as appropriate for the work to be undertaken:- a. Where the confined space is part of a steam, HTHW or MTHW boiler, which is one of a range of two or more such boilers, either:- And All inlets from which a relevant fluid (steam, HTHW or MTHW Compressed Air, large refrigeration system etc) might otherwise enter the boiler from any other part of the system have been disconnected from that part by the closing of two valves in series (double valving). Or Where a system of double valving cannot be utilised, suitable blanks have been installed such that one valve plus one blanking plate are incorporated. Where 'double valving' is utilised but the pipe is to remain open-ended for extended periods, a blanking flange shall additionally have been fitted. All blanking flanges shall incorporate the facility to prove that they are not subjected to system pressure before removal. Personal Protective equipment, in the form of full overalls, gloves and a full face mask shall be worn by any person fitting blank flanges or when 'cracking open' joints when the pipework involved is not protected by 'double valving'. b. That all aspects of The Confined Spaces Regulations 1997 have been considered and suitable arrangements made. No person shall enter a boiler or air receiver unless a suitable and sufficient Risk Assessment has been carried out and a resulting Safe System of Work is put into practice. e. The requirements above are equally applicable to Compressed Air systems, Air Receivers and large Refrigeration systems. Oct 09 Page 13 of 13

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