Safe Steam IntroUninterrupted safety and efficiency

35 Slides

Safe Steam IntroUninterrupted safety and efficiency

35 Slides

Radiant RealitiesTim Blomdahl

Safety is a condition. A mindset. Aproduct of personal dedication.

NBIC Bulletin winter 2016

Oregon boilerand pressure

vessel law

The Intent of Oregon Adopted Code

• Protect the public• Protect property• Fire safety• Ensure safe construction• Safe installation• Safe maintenance• Accessibility• Healthy environments• Efficiency

• Protect the public• Protect property• Fire safety• Ensure safe construction• Safe installation• Safe maintenance• Accessibility• Healthy environments• Efficiency

To View Code: Googleasme.bpvc.i.a.2011.pdfChoose Sitelaw.resource.org/pub/us/code

2013 Current Edition

Radiant Realities 5

To View 2007 Code: Googleasme.bpvc.iv.2007.pdfChoose Sitelaw.resource.org/pub/us/code

H

To View Code: Googleasme.bpvc.vi.2010.pdfChoose Sitelaw.resource.org/pub/us/code

To View Code: Googleasme.bpvc.vii.2010.pdfChoose Sitelaw.resource.org/pub/us/code

Current Adopted Oregon Law2012 ASME CSD-1

Boilers up to 300 hp

•Assembly•Installation•Maintenance•Operation

General CG

Radiant Realities 9

TestingMaintenance

CM

Electrical CESteam

WatersideCW

CombustionCF

Boilers and burnersabove 12,500,000

btus (300 hp)www.nfpa.org/freeaccess

Radiant Realities 10

2012 CurrentAdopted Edition

2012 CurrentAdopted Edition

11

2013 NBICNational Board Inspection Code• Part 1 Installation• Part 2 Inspection• Part 3 Repairs/Alterations

Nationalboard.org

NBIC 2007

18

19

Develop a Safety Program

• The goal of every safety program is tominimize the risk associated with boiler

operation.

• Danger is a given in regards to boilers.

• The goal of every safety program is tominimize the risk associated with boiler

operation.

• Danger is a given in regards to boilers.

Boiler risk managementIssues develop over time and can be overlooked• Low water- (Dry firing)• Safe lighting of main flame• Scale accumulation• Corrosion• Sediment (Cycles of evaporation)• TDS(Water softener failure, treatment issues)• Poor water circulation within the boiler• Excess steam load… (Overloaded burners)• Safe purge cycles

Issues develop over time and can be overlooked• Low water- (Dry firing)• Safe lighting of main flame• Scale accumulation• Corrosion• Sediment (Cycles of evaporation)• TDS(Water softener failure, treatment issues)• Poor water circulation within the boiler• Excess steam load… (Overloaded burners)• Safe purge cycles

Safe Operation of Boilers

• Is the boiler equipped with all of the safetydevices required for safe automatic firing.

• Is the boiler installed to code piping safetyrules. BEP, NBEP pipe and fittings.

• Are the controls tested and maintained.

• Is the boiler equipped with all of the safetydevices required for safe automatic firing.

• Is the boiler installed to code piping safetyrules. BEP, NBEP pipe and fittings.

• Are the controls tested and maintained.

Safety SystemsEvery system is unique and requires a

set of safety rules that apply tospecific operating parameters'

Operate the boiler with agood set of safety rules

• Avoid unsafe practices.• Evaluate the risks and decide on precautions.• Understand potential hazards and danger.

• Avoid unsafe practices.• Evaluate the risks and decide on precautions.• Understand potential hazards and danger.

Look for potential hazardsA good operator studiestheir plant every day for

possible safetyproblems!

Look for potential hazardsA good operator studiestheir plant every day for

possible safetyproblems!

Safety hazards

• Unusual noise• Fuel leaks• Steam leaks• Water leaks• Water hammer

• Unusual noise• Fuel leaks• Steam leaks• Water leaks• Water hammer

What do boiler systems need?

Attention!Pay Attention

Attention!Pay Attention

Safe today?

1. It’s not about how well the systemperformed yesterday.

2. It’s about is the system safe today?

3. How do I know?

1. It’s not about how well the systemperformed yesterday.

2. It’s about is the system safe today?

3. How do I know?

Human factor

• Operation, maintenance, and people issuesare by far the biggest combustion safety issue.

• 40% of all deaths and accidents are caused byhuman error or poor maintenance.

• Codes offer very little specific direction inregards to training, other than to say trainingit is required and should be done regularly.

• Operation, maintenance, and people issuesare by far the biggest combustion safety issue.

• 40% of all deaths and accidents are caused byhuman error or poor maintenance.

• Codes offer very little specific direction inregards to training, other than to say trainingit is required and should be done regularly.

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Objectives

• Extend operating life of the equipment.• Reduce the cost of ownership.• Enhance system efficiency.

Objectives

• Extend operating life of the equipment.• Reduce the cost of ownership.• Enhance system efficiency.

Common practices that should befollowed to avoid destroying a boiler

• Frequently observe the burner flame. Look forsmoke, or soot, flame impingement, furnace andrefractory condition.

• Always investigate the cause of burner tripsbefore numerous attempts to relight .

• Never use untreated water in the boiler.• Verify that the water treatment system is

operating properly• Continually monitor the quality of condensate

returning to the boiler• Monitor continuous BD conductivity• Verify the water leaving the DA is free of oxygenNBIC Bulletin article “How to destroy a boiler.”(Nationalboard.org)

• Frequently observe the burner flame. Look forsmoke, or soot, flame impingement, furnace andrefractory condition.

• Always investigate the cause of burner tripsbefore numerous attempts to relight .

• Never use untreated water in the boiler.• Verify that the water treatment system is

operating properly• Continually monitor the quality of condensate

returning to the boiler• Monitor continuous BD conductivity• Verify the water leaving the DA is free of oxygenNBIC Bulletin article “How to destroy a boiler.”(Nationalboard.org)

A boiler system does not care if:

• You have been an operator for 30 years• Your service company has one of the best

records in the State of Oregon• Your inspection skills are impeccable• You have more knowledge than any other

human being in regards to pressure systems• You are conscientious and just plain brilliant

Boiler systems need to be monitored, tested,maintained and paid attention too!

• You have been an operator for 30 years• Your service company has one of the best

records in the State of Oregon• Your inspection skills are impeccable• You have more knowledge than any other

human being in regards to pressure systems• You are conscientious and just plain brilliant

Boiler systems need to be monitored, tested,maintained and paid attention too!

Develop unique safety checklists• Water level• Steam pressure• Burner firing rate• Main gas pressure• Burner supply gas pressure• Burner flame condition• Flue temperature• Feedwater temperature• Feedwater tank water level• Feed pump discharge pressure• Makeup water usage• City water pressure• Post and pre-purge operation

• Water level• Steam pressure• Burner firing rate• Main gas pressure• Burner supply gas pressure• Burner flame condition• Flue temperature• Feedwater temperature• Feedwater tank water level• Feed pump discharge pressure• Makeup water usage• City water pressure• Post and pre-purge operation

Radiant Realities 34

Successful training reducesaccidents, improves reliability, and

improves efficiency, productivity andthe bottom line.

Successful training reducesaccidents, improves reliability, and

improves efficiency, productivity andthe bottom line.

The human side of energy efficiencySteam Digest 2002