Boiler tube leaked, what need to do?

If a boiler tube leak occurs, procedures under DOSH (Department of Occupational Safety and Health, Malaysia) must be strictly followed, since boilers fall under the Factories and Machinery Act (FMA) 1967 and Occupational Safety and Health Act (OSHA) 1994. 

Here’s the typical procedure:

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1. Immediate Actions (During the Incident)

• Shut down the boiler safely

  • Stop firing immediately.

  • Trip fuel supply (oil, gas, biomass, coal).

  • Isolate steam flow and reduce pressure gradually.

  • Maintain feedwater if possible to prevent overheating of tubes.

• Evacuate and secure the area

  • Prevent workers from entering the boiler house due to risk of scalding/steam release.

• Report to the competent person (Boiler Engineer / Chargeman / Boilerman).

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2. Notification to DOSH

• Mandatory reporting:

  • A boiler tube leak is considered a dangerous occurrence under Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations 1970.

  • The employer must notify the nearest DOSH office immediately (usually within 24 hours) and submit a written report (Form JKKP 6 or relevant form).

• If injury or fatality occurs → also report under Occupational Safety and Health (Notification of Accident, Dangerous Occurrence, Occupational Poisoning and Occupational Disease) Regulations 2004.

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3. Inspection & Investigation

• The Competent Person (CP) (Boilerman/Steam Engineer certified by DOSH) must:

  • Inspect the boiler after shutdown and cooling.

  • Record tube failure location, cause, and possible hazards.

• DOSH may send an officer for site inspection.

• Root cause analysis must be conducted (erosion, corrosion, scaling, overheating, poor water treatment, etc.).

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4. Repair & Rectification

• Boiler tube repair/replacement must be carried out by a DOSH-approved Repairer (with approval under Regulation 8, FMA 1970).

• After repair, the boiler must undergo:

  • Hydrostatic Test witnessed by DOSH Inspector or CP.

  • Non-destructive Testing (NDT) if required.

• Repair report and test certificates must be submitted to DOSH.

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5. Re-commissioning

• Boiler cannot be restarted until written clearance from DOSH is obtained.

• Competent Person must update Boiler Logbook (as required by law).

• Preventive measures must be implemented (e.g., improved water treatment, scheduled inspections, NDT).

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✅ In summary:

1. Shut down and make safe.

2. Notify DOSH immediately.

3. Investigate with Competent Person.

4. Repair only by DOSH-approved repairer.

5. Hydrostatic test + DOSH clearance before restarting.

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