Boiler Inspector Combustion Safety Awareness Tool Beyond Standard Jurisdictional Inspections

10 Deadly Sins of Combustion Systems & How to Avoid Them

Most mandated jurisdictional boiler inspections only consider pressure vessel related issues. This document is intended as a support tool for risk engineers and jurisdictional boiler inspectors to assist in the assessment of combustion related issues that might be outside of their normal scope of work. The pictures and situations presented are intended to point out typical unwanted circumstances related to combustion system safety that may help you to offer more value to your customers inspection visit and reduce risks at their facilities.

All of the 10 deadly sins illustrated herein are real-life examples of what auditors at CEC Combustion Services Group, Inc. (CEC) have come across when evaluating the safety of combustion equipment. All of these examples may make for a dangerous working environment that could result in a fire or explosion under the right conditions.

11699 Brookpark Road - Cleveland, Ohio 44130 - 216.749.2992 - Fax 216.398.8403 www.combustionsafety.com

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1. Tightness Testing of Safety Shutoff and Blocking Valves is not being done. Picture 1a Picture 1b

The photographs show evidence of valve testing ports that do not appear to have ever been removed. This is an obvious sign that the required tightness testing is not taking place. Gas trains keep gas out of the combustion chamber when equipment is off through a series of tight closing, specially designed shut-off valves that are spring loaded to close. These are the safety shutoff and blocking valves. Equipment Standards/Codes and laws require these valves to be tightness tested on a regular basis. Auditors at Combustion Safety, Inc. find that sites are either not performing the testing altogether or are improperly testing the safety shut-off valves. Leaking gas through these values into a combustion chamber can enhance the chance of an explosion.

Combustion Safety Product/Service Reference: Tool Kit for testing Interlock & Tightness testing Training

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CEC Combustion Services Group

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2. Critical safety components can be jumpered out and/or unreliable documentation may exist. Picture 2a Picture 2b

Picture 2c

Picture 2d

The photographs show evidence of either poor wiring installations or poor documentation practices. Photograph 2a indicates circumstances where wiring is not labeled properly and modifications were made that may not be correct or accurate in addition to being extremely sloppy. Prints need to be neatly updated and verified such that they can be understood by an electrician without a higher than normal probability of error. The wiring diagram shown in photo 2b identifies one that has been customized in the field. This may or may not be an authentic controlled version of what really is in the panel. Photos c) and d) indicate bypassed safety circuits. In the case of photo 2c, an obvious electrical jumper exists that bypasses a control. Its a wire that is not the same as the others, is connected with alligator clips, and is of a different gauge and color. In photo 2d a Popsicle stick is broken off and jammed into a pressure switch contact to hold the contract closed.
Combustion Safety Product/Service Reference: As Built wiring documentation services Training

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CEC Combustion Services Group

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3. Obsolete Burner Management Systems (BMS) can make for long outages and incomplete protection. Picture 3a Picture 3b

The burner management system (BMS) in photograph 3a is a new model RM7800 from Honeywell. The version on the right is an older model Honeywell. The version on the right is typical of a model that is out of production with components that are no longer available from the manufacturer. Should this obsolete BMS fail a replacement will not be available which means engineering time to design a new wiring configuration and panel modifications to accept a newer BMS. Most sites could not afford this amount of down time to their processes. Additionally equipment has also been recalled or important safety advisories have been issued. A listing of these types of issues, including some recall notices and service advisories, is available on our website under the Resource Center at www.combustionsafety.com.

Combustion Safety Product/Service Reference: Gap Analysis Upgrades Implemented Website safety alerts www.combustionsafety.com

Combustion Mechanical, LLC

CEC Combustion Services Group

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4. Valves in the instrument lines can render switches / instruments ineffective. Picture 4a Picture 4b

Valves in instrument lines can be left in the closed position rendering switches out of service and functionally incapable of operating. They should always be removed or at least locked open as soon as they are found. This especially applies to high/low gas, and steam pressure switches, bleed vent lines, and water column connections.
Combustion Safety Product/Service Reference: Tool kit for testing Interlock Tightness testing Training

5. Set points are obviously wrong can render switches/instruments ineffective Picture 5a Picture 5b

Instruments and safety devices without correct set points provide little to no protection. Switches that have the set point at the extreme range of the switch are either set incorrectly or the wrong switch is being used.
Combustion Safety Product/Service Reference: Equipment commissioning Documentation

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CEC Combustion Services Group

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6. Flame roll-out (hard starting) can be a warning for dangerous conditions that may get worse. Picture 6a

When the bottom of equipment is burned or scorched it may indicate flame rollout. This occurs when flues are blocked, mixtures are set incorrectly or combustion air to the boiler room is inadequate. In these cases combustible mixtures exist outside of the firebox.
Combustion Safety Product/Service Reference: Tool kit for testing Interlock Testing Gap Analysis

7. Automatic valve actuator failure (Safety Shutoff, Blocking Valve, Pilot or Vent Valves) can make for downtime and hazardous operating conditions. Picture 7a Picture 7b Picture 7b

Hydraulic valve actuator failures are sometimes indicated by the presence of hydraulic fluid on the valves exterior. These photographs show oil stains on the sides of valves (7a), puddling at the valve body (7b) and obvious excessive leakage with residual under the equipment (7c). When you find this condition it indicates that some of the actuators hydraulic fluid has leaked out. These valves are usually spring-loaded to close (not needing the hydraulic fluid for closing). The risk here is mostly one of equipment downtime when you least expect it since the hydraulic fluid is needed to open the valve to light the unit.
Combustion Safety Product/Service Reference: Tool kit for testing Interlock Tightness testing Training

Combustion Mechanical, LLC

CEC Combustion Services Group

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8. Lubricated Plug Valves can be leaking through in the closed position or be frozen in place and inoperable. Picture 8a Picture 8b

Picture 8c

Picture 8d

Picture 8e

Picture 8f

Lubricated plug valves fail in a number of ways including leaking through when in the closed position and by being seized. Inspections at more than 400 sites found that more than 60% leaked through in the closed position. A typical plug valve showing the body, plug, and lubricant coating on the plug that makes the seal is shown (8a). A frozen valve that cannot be closed in an emergency is indicated in (8b). Proper valve sealant inject gun is shown in (8c). A valve that has been painted shut with no handle is shown in (8d) and (8e). A valve in the closed position that is leaking through the inside of the pipe downstream is indicated in (8f).

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CEC Combustion Services Group

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Lubricated plug valves need to be properly maintained on a regular basis. This means injecting the proper sealant material and making sure the valves are exercised.
Combustion Safety Product/Service Reference: Valve sealants, injection tools, and valve service videos in stock Internet Super Store

9. Vent Valves can be failed open disrupting operating conditions putting live fuel on to roofs and improper mixtures into burners Picture 9a Picture 9b

Normally open vent valves are installed in gas trains to improve safety when equipment is off (9a). They allow gas leakage through the first automatic valve to get outside instead of to the firebox. When the burner tries to light they are supposed to close tight so all the gas goes to the burner. If they are failed and leaking they can be venting natural gas from the gas train while the burner is trying to operate (9b). This makes for risks on the roof from ignition sources, not optimum performance from the burner as well as increased fuel cost from the venting of the gas. We have found burners with unstable flames that cannot stay lit because of the pressure loss due to a failed vent valve. If an unstable flame happens back-up systems must recognize the loss of flame and be called upon to shut gas off. If these fail the risk of an explosion is increased.
Combustion Safety Product/Service Reference: Tool kit for testing Interlock Tightness testing Training

Combustion Mechanical, LLC

CEC Combustion Services Group

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10. Outside Vent Terminations can be blocked with insect nests. Picture 10a Picture 10b

Picture 10c

Most instruments and switches are vented devices that require pipes routed to safe locations outdoors (10a). This allows for proper operation of the device and for gas to escape if a diaphragm failure occurs. Vent terminations are often found to be unprotected which increased the risk of blockage and restrictions due to insect nests (10b) and moisture entry. A clogged vent may mean that there is inadequate relief of gas when a component fails which may result in the component not providing the protection required. Entry of moisture will result in premature automatic valve failure from foreign contaminants and rust. Safety Codes require protected vent terminations (10c) with screening devices be installed that are turned down to prevent entry of moisture.
Combustion Safety Product/Service Reference: Most all popular vent screen sizes are stocked and can be shipped overnight

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CEC Combustion Services Group

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GAS AND COMBUSTION SYSTEM EXPLOSIONS CAN BE AVOIDED

Hopefully, you are not a combustion system sinner. If you are, salvation can often be found in the form of awareness and training. It is also most likely going to take a culture change at your facility and a new found respect for this equipment. Consider the case of a lowly 100 gallon hot water heater. The energy stored in a 100 gallon hot water can be equivalent to 10 sticks of dynamite. If you really had 10 sticks of dynamite stored at your facility you would treat it with a great deal of respect.

Please let this not be your first and final combustion equipment soul search but instead only a wake-up call. This area of safety is not like fall protection or making employees wear safety glasses. This equipment has the power to destroy many people and property on a massive scale. It only gives you one chance. If you fail at your one chance it can mean death and destruction for those that may be working on or near the equipment as well as many innocent bystanders. You must find these few minutes to review your site!

For more information contact: CEC Combustion Services Group 11699 Brookpark Road Cleveland, Ohio 44130 Phone: 888.826.3473 Fax: 216.398.8403 www.combustionsafety.com

Combustion Mechanical, LLC