Using Propane Safely e-learning reference material

Guide Book Series

Bitumen boilers

Bitumen Boilers Key safety issues

When the cylinder and boiler have been secured in a safe area, and the regulator and armoured hose have been connected to the cylinder, the operator can now visually inspect the burner and attach it to the armoured hose using the correct spanner. Before lighting the burner it is essential that the operator checks that it will easily fit inside the boiler prior to lighting the system. If there’s a blockage inside the boiler it’s easier to sort out the problem before the burner is lit. Once the operator is sure the burner will fit into the boiler they can turn on the propane cylinder by slowly opening the cylinder valve. The valve may be opened fully and then turned back half a turn. The burner can now be lit using the correct type of spark lighter. Once the burner is lit is can then be safely inserted into the boiler. Now the burner is inside the boiler the operator can safely leak test the connections downstream of the cylinder. Firstly the operator should leak test the connection between the regulator and the cylinder valve. Then they should check the connection between the armoured hose and the regulator. If a leak is found the system should be safely shut down and the leak rectified. Finally they should carefully leak check the connection between the armoured hose and the

This information is for guidance only. Operators should always follow the boiler manufacturer’s operating instructions as well as an authorised standard operating procedure for correctly setting up the system. The cylinder set-up and boiler lighting must only be undertaken in a safe, well ventilated area by trained operators who are wearing the correct personal protective equipment.

The operator should visually inspect the boiler for damage prior to starting the job. Damaged boilers should not be used. Operators should also check that the vents are clear of excess tar. Next the operator should check that the gas cylinder is correctly labelled or stencilled as propane. The cylinder should be secured on a flat, level surface and must be at least 3m away the boiler. The cylinder must also be upwind of the boiler and should be sited so that a spillage of bitumen could not reach it. The operator can now remove the valve protector/plug and visually inspect the valve for damage and/or contamination. If either is found then the cylinder should not be used. The propane regulator should be visually inspected to ensure that it isn’t damaged, is in-date and will deliver the correct working pressure to the boiler. If the regulator is suitable for service it can be fitted into the cylinder valve outlet and secured with the correct sized spanner, preferably not an adjustable spanner. Some regulators designed for bitumen boilers are supplied with an armoured hose already attached. It is strongly recommended that an armoured hose is used with bitumen boilers and standard rubber hoses could ignite if they came into contact with hot bitumen. Operators should always visually inspect the armoured hose for damage before use. Damaged hoses must not be used. 22

At the end of work it is essential to shut the system down safely. A common practice with many types of equipment is to close the cylinder valve first and then allow the residual gas to burn off at the torch/burner. After the flame burns out the operator can close any valves fitted to the equipment and carefully disassemble it.

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