Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
1
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!!!
2
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. . .
3
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…
4
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
5
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?
6
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
7
You think your boiler inspector is
1
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
8
United States Boiler LawASME CSD-1 Adopted
No
Yes
Other Codes Also Call For Testing
Codes and technology for safety have
2
Codes and technology for safety have changed, you still have archaic
primitive equipment!
Where do I turn to find out the requirements?
9
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
10
Why Regular Inspection Is VitalWhy Regular Inspection Is Vital
You are probably not testing
3
p y ginterlock controls!
Based on 2,000+ Field Inspections
New ProgramsUnsafe device failure on 50% of equipment
11
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?
12
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
13
You probably don’t have d
4
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
14
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
5
Critical safety component recalls, safety advisories, and obsolete
equipment out there!
This Includes Valve ManufacturersThis Includes Valve Manufacturers
15
Burner Management Systems
Product Safety Notice
www.combustionsafety.com
Your safety shutoff valves are b bl t b i ti ht
6
probably not being tightness tested.
16
Valve Tightness Is CriticalValve Tightness Is Critical
Seat
Seat Leakage IssuesSeat Leakage Issues
Valve Tightness Testing
17
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
18
Your manual shut off valves
7
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
19
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!
20
Properly Maintained?What happens if this unit needs repaired?
You are Required To Train
8
You are Required To TrainYour Operators/Staff on Combustion Equipment!
Question
What is the most important safety on a
unit?
21
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
22
You probably don’t have clear,
9
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
23
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
10
know much about safe gas piping repair!
24
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?
25
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
26
Questions?
www.combustionsafety.com216.749.2992
Copyright © 2008 CEC Combustion Safety, Inc. All rights reserved