Effective control of hazards related to steam boilers used in manufacturing industries in Sri Lanka

Abstract

Effective control of hazards related to steam boilers used in manufacturing industries in Sri Lanka Steam Boiler (SB) is the major equipment use in a steam system. It is a pressurized vessel in which heating of water take places and generates steam. It is operated under high heat and high pressure. Therefore, it is considered as dangerous equipment. Many incidents have been reported around the world. This study is focused to control Steam Boiler related hazards found in manufacturing industries in Sri Lanka, by revealing measures to enhance Steam Boiler manufacturing and operation. A literature survey, a detailed questionnaire survey, and expert interviews were used to collect data. The pilot survey was conducted to make necessary adjustments and validate the questionnaires. Hundred and twenty manufacturing industries were selected as sample. This study sample was selected among the manufacturing industries registered in the Industrial Safety Division of Department of Labour. This was included sixty factories with Steam Boiler related incidents. Steam Boiler related incidents were not reported in other sixty factories. Questionnaire was given to all selected factories and results were analysed using Graphical and Relative Important Index method (RII). Graphical method was used to evaluate the available work practises and RII method was used to identify critical causes of those incidents. Expert interviews were conducted to find expert opinions regarding Steam Boiler operation procedure and manufacturing procedure. Steam Boiler related hazards are classified as Accidental, Physical, Biological, Chemical, Ergonomic and Psychosocial factors. Only accident type hazards, such as structural explosions, steam leakages fuel leakages were reported in Sri Lanka. The highest number of hazardous incidents was reported in rice mills. Both unsafe actions and unsafe conditions had caused to those incidents. Hazards incidents were not reported in factories with good work practises. Finally, expert suggestions and study results were used to propose strategies to enhance standard of Steam Boiler operation procedure and manufacturing procedure.