boiler and combustion safety: what you don’t know can kill

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Boiler and Combustion Safety:What You Don’t Know

www.combustionsafety.com

CAN Kill You!

CombustionSafety, Inc.

Agenda

Importance of Combustion Safety

10 Common Combustion Hazards

Where To Go From Here?

Because, They Don’t Know!!!

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Facility LossDead / Injured

Human Error

Equip. Failure

Lack of Training

Poor Maint.

Improper Procedures

High Risk Culture

Central Powerhouse Complex $2 Billion 6 / 14 X X X X

Algerian LNG $800 MM 31 / 74 ? X X X X

Kaiser Aluminum $300+ MM 0 / 23 X X X X X

Kansas City P&L $196 MM 0 / 2 X X X

Just A Few Numbers

Tosco Refinery $71 MM 1 / 46 X X X X

New River Casting $30 MM 3 / 7 X X X

GM Lordstown N/A 1 / 0 X X X X X

Crown Cork & Seal $20 MM 0 / 1 X X X X X

Case #1: Powerhouse Explosion

Root Cause:– Open valve leaked gas into fire box– Ignition source

Secondary Root Causes:– Numerous Disconnected & Failed Safety

Interlocks, some since ‘66– Missing SOP’s– Lack of Training– Poor Inspection/Testing ProgramPoor Inspection/Testing Program– Four Consultant Reports Ignored

Case #1: Explosion “Ripple” • 6 Dead & 14 Injured

• $2,000,000,000+ in Fines, Lawsuits, Litigation, Lost market Share, Self Insurance, Business Interruption, and misc. costs

• 42 Plants Shutdown

•February 1, 1999

• Lost Production

– Shifts Cut in half at various plants

– Eliminated scheduled overtime

•John Arseneau

– Relied Upon Inventory for Premium Product

• Dropped Stock Value – 10% and did not recover for 3 months to pre-explosion marks.

• Impact of Strained Corporate Moral. . .

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Case #2: Financial Impact

Root Cause:– Build-up of Gas– Hot Fire box

Secondary Causes:– Lack of Hazards

Training– Human Error

Growth Creates Safety Gaps

Greater Gaps with Recently Acquired Sites – Nonexistent or limited combustion

programs, training, standards, & enforcementL f i d t hi h

Case #3: Expansion / Growth

– Loss of experience due to high personnel turnover

– Lack of spending prior to acquisition

– Loss of equipment documentation

But I Have Safety Devices Installed…

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What A Fuel Train Is And What It Does

Fuel trains are assemblies of components, piping, and controls that provide the same basic functions for fuel fired equipment…

1. Shut down immediately if a safety interlock trip occurs.

2. Keep fuel out of the firebox when equipment is off.

3. Control combustion process4 S f li ht ff

Fuel Train Functions

4. Safe light offs

•Venting of components not shown for clarity

Main/Pilot Fuel Trains

Flow MGSSV2MGSSV1

Venting of components not shown for clarity

Main Burner

Pilot Burner

PGSSV1 PGSSV2

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What About An Overall Gas Train Supervisor?

What About An Overall Gas Train Supervisor?

Interlocks/PermissivesInterlocks/Permissives

Inputs Outputs

Firing Rate Controller

Firing Rate Valve Position

Burner ManagementSystems (BMS)

Flame Safeguard

System

Interlocks Conditions

Flame Signal

Ignition Trials

Pilot Valves

Main Valves

What About A Flame Detector?

Characteristics of a flame for detection?

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Pressure Switches

What About Controlling Combustion?

PressureRegulator

Just having the devices is not enough!

But what else do I need?

The 10 Biggest Fuel andThe 10 Biggest Fuel and Combustion Equipment

Problems

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You think your boiler inspector is

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y pkeeping you safe, but….......

Your boiler inspector is not who you think he is!

You Think He’s a Boiler Superman! Protecting life and limb…

ASME I Thru IXASME I Thru IX

Juridictionals have a very limited scope!!!

NOYes

Fire SideFire Side

Gas TrainsGas Trains

And Jurisdictional Inspections

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United States Boiler LawASME CSD-1 Adopted

No

Yes

Other Codes Also Call For Testing

Codes and technology for safety have

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Codes and technology for safety have changed, you still have archaic

primitive equipment!

Where do I turn to find out the requirements?

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Codes & Standards

Minimum Consensus Standards - Built on a foundation of maximum participation and agreement by a broad variety of interests.

OSHA Act: “the Secretary shall… by rule promulgate as an occupational safety or health standard any national standard…”

National Fire Protection Association (NFPA)NFPA 85 – Boilers (> 12 5 MMBtu)

Standards Developing Organizations

NFPA 85 Boilers (> 12.5 MMBtu)NFPA 86 – Ovens & Furnaces

American Society of Mechanical Engineers (ASME)ASME CSD-1 – Boilers (0.4 to 12.5 MMBtu)

• Occupational Safety & Health Administration (OSHA)

A li bl St t & L l A th iti

Authorities Having Jurisdiction (AHJ)

• Applicable State & Local Authorities

• Jurisdictional Boiler Inspector

• Corporate Insurance Provider

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Why Regular Inspection Is VitalWhy Regular Inspection Is Vital

You are probably not testing

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p y ginterlock controls!

Based on 2,000+ Field Inspections

New ProgramsUnsafe device failure on 50% of equipment

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These Are Device Failures Like:

• Gas high pressure / low pressure switches• Low fire start switches• Flame supervision/scannersFlame supervision/scanners• Combustion air switches• Proof of closure switches on gas valves• Low water cut offs

Testing Means Simulating Conditions To See If Safeties Work

But if devices fail, will equipment run?

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Bypassed Purges

What do we mean by purging?

Purging

Fresh Air Purge

Successful Purging Furnaces = at least 4 firebox volume changesBoilers = Varies based on type and # of burners

Combustion Chamber Fan Capacity

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You probably don’t have d

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adequate system documentation

Is This Pressure Switch Set Correctly?People’s Lives Depend On The Answer!

Proper documentation is vital!

And Is This What Your PanelsLook Like?

Often no wire numbers, accurate schematics, or as built drawings

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Want Human Error?

Then let this be the “as builts” your staff troubleshoots from!Then let this be the “as builts” your staff troubleshoots from!

Critical safety component recalls

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Critical safety component recalls, safety advisories, and obsolete

equipment out there!

This Includes Valve ManufacturersThis Includes Valve Manufacturers

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Burner Management Systems

Product Safety Notice

www.combustionsafety.com

Your safety shutoff valves are b bl t b i ti ht

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probably not being tightness tested.

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Valve Tightness Is CriticalValve Tightness Is Critical

Seat

Seat Leakage IssuesSeat Leakage Issues

Valve Tightness Testing

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Fuel Gas SSOV’S(Leak Testing - Bubbles Per Minute)NominalDiameter

ANSIB16.104 VIFCI 70-2VI

UL-429CSA 6.5 FM7400

0 75” 1 26 3 1470.75 1 26 3,1471.00” 1 26 3,1471.25” 1 26 3,1471.50” 2 39 3,1472.00” 3 52 3,1472.50” 4 65 3,1473.00” 6 78 3,1474.00” 11 104 3,1476.00” 27 157 3,147

Leak Test measurements are performed based on a 1/4” x .032 wall

Has Yours Been Tested Lately?Has Yours Been Tested Lately?

Apparently Not!

Tightness Testing Plug

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Your manual shut off valves

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probably don’t work and are not being maintained properly !

They Also Leak Through, A Lot!

• We find 60% of plug valves leak through when in the closed position.

• Many do not own equipment to seal / lubricate valves• Many do not own equipment to seal / lubricate valves.

Common Manual Shut Off Valve

BodyBodyPlugPlug

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It’s Only The Sealant That Makes It Work

You’ll Need Equipment Like This

Valve Servicing & Maintenance Tools

It’s not just grease!

It Has To Move When You Need It To!

But 10% Won’t!

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Properly Maintained?What happens if this unit needs repaired?

You are Required To Train

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You are Required To TrainYour Operators/Staff on Combustion Equipment!

Question

What is the most important safety on a

unit?

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Answer :

A well trained operator!

Training

2011 NFPA 86 Process OvensSection 7.3.3Personnel who operate, maintain, or supervise the furnace shall receive regularly scheduled refresher training and shall demonstrate understanding of the equipment, its operation, and practice of safe operating procedures in their respective job functionsoperating procedures in their respective job functions.

NBIC StatisticsOBJECT EXPERIENCING INCIDENT ACCIDENTS INJURIES DEATHSSafety Relief Valve 245 26 2Low Water Cut Off 7,640 22 0Limit Controls 761 25 4

This Stuff Can Kill And Hurt People!

Limit Controls 761 25 4Improper Installation 638 51 3Improper Repair 544 54 8Faulty Design or Fabrication 611 48 12Operator Error or Poor Maintenance 4,987 164 27Burner Failure 866 55 11GRAND SUBTOTALS 16,292 445 67

www.nationalboard.org

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You probably don’t have clear,

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simple Start-Up And Shut Down Procedures.

Ok, So What Do I Bump, HitTurn, Or Nudge To Get This Started?

This is NOT Really MeaningfulThis is NOT Really Meaningful

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It Must Be Clear / SimpleIt Must Be Clear / Simple

Equipment Pre-Start Walk-Around

It is good practice to perform a walk-around of your equipment prior to start-up. This should especially be done after a unit has been down due to maintenance, repairs, or on extended down time. This walk-around should attempt to identify any deviations from normal operation/condition of the equipment. The following checklist should be used to identify these issues. Note: This checklist is not specific to any particular piece of fuel-fired equipment but should be used as a guideline only. Equipment specific walk-arounds should be generated for each piece of equipment.

A. Review control panel lights, markings, and internal wiring. Look for jumpers across terminals and relays that may be blocked/jammed open.

"15 Minutes To Save Your Life” Pre-Start Walk Around"15 Minutes To Save Your

Life” Pre-Start Walk Around

y y j pB. Review all safety interlock switch settings to make sure they appear reasonable; (as per marked

settings).C. Review all valves (manual gas cocks and safety shut-off valves) to make sure they are in the proper

position prior to start-up (i.e. safety shut-off valve visual indication shows closed).D. Review that all sensing lines to interlock switches, ratio regulators, and other devices are connected.E. Review all firebox and/or entrance doors to combustion chamber or furnace/oven chamber to make

sure all are latched properly.F. Review fan dampers so that they are free to move and are not jammed. Check that all filters are

unclogged and in place. Check fan blades and general fan condition. See if purge fans are moving air.G. Review exhaust system fans, dampers, and related components.H. Locate the termination of each vent/bleed line. Review for gas flow and inset/bird nests (or other type

of blockage).I. Check the time settings on all purge timers.J. Do a no fuel ignition sequence if possible to see that BMS sequences properly.

©2000 CEC Consultants, Inc.

Your people probably don’t k h b f

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know much about safe gas piping repair!

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Gas Is Different!

• Electrical wires don’t need to be purged after shutdown gas doesshutdown – gas does

• Breaker contacts open - evidence that it is off –not gas

• Most electrical panels, one lock fits all - not gas

And Don’t Forget About Lockout Equipment for Gas Valves!

Built Into Valve

Fits On to Valve

Built Into Handle

Many Types

Is It Open or Closed?

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OK, So Now You Know a Lot, Now What?

LegalR i t

Expectations/Responsibilities

Requirements

Changing the Safety Culture

Elements of a Successful Culture

• Identify and implement measures to reduce risks

• Recognize hazards – don’t be apathetic!

• Improved awareness – no shortcuts!

• Training and Preventative Maintenance (PM) programs

• Keep current with safety standards

boiler and combustion safety: what you don’t know can kill

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