FM Global Property Loss Prevention Data Sheets

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OIL- AND GAS-FIRED SINGLE-BURNER BOILERS

Table of Contents
Page 1.0 SCOPE ................................................................................................................................................... 2 1.1 Changes ............................................................................................................................................ 2 2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2 2.1 Introduction ...................................................................................................................................... 2 2.2 Equipment and Processes .............................................................................................................. 3 2.2.1 Combustion Air and Preignition Purge .................................................................................. 3 2.2.2 Igniters, Safety Shutoff Valves, and Combustion Safeguards .............................................. 3 2.2.3 Additional Safety Controls ..................................................................................................... 4 2.2.4 Additional Recommendations for Gas Firing ........................................................................ 5 2.2.5 Additional Recommendations for Oil Firing ........................................................................... 5 2.2.6 Gas-Fired Multiport Burner Grid ............................................................................................ 7 2.2.7 Flue Gas Recirculation Interlocks ......................................................................................... 7 2.3 Protection ......................................................................................................................................... 8 2.4 Operation and Maintenance .......................................................................................................... 10 2.4.1 General ................................................................................................................................ 10 2.4.2 Alternate and Simultaneous Fuel Systems ......................................................................... 11 2.4.3 Flue Gas Recirculation ........................................................................................................ 13 2.5 Electrical ........................................................................................................................................ 14 3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................. 14 4.0 REFERENCES ..................................................................................................................................... 15 4.1 FM Global ...................................................................................................................................... 15 4.2 NFPA Standards ............................................................................................................................ 15 4.2 Other Standards ............................................................................................................................ 15 APPENDIX A GLOSSARY OF TERMS ..................................................................................................... 15 APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 15 APPENDIX C SUPPLEMENTAL INFORMATION ...................................................................................... 16 C.1 Igniters .......................................................................................................................................... 16 C.2 Safety Shutoff Valves .................................................................................................................... 16 C.3 Other Standards ............................................................................................................................ 17

List of Figures
Fig. 1. Fig. 2. Fig. 3. Fig. 4. Fig. 5. Single-burner automatic-lighted gas-fired boiler. Example of a permissive start and firing sequence. . 6 Schematic. Typical gas-fired piping arrangement over 2.5106 Btuh (732 kW). ............................... 7 Single-burner automatic-lighted oil-fired boiler. Example of a permissive start and firing sequence. . 8 Schematic. Typical oil-fired piping arrangement over 2.5106 Btuh (732 kW). ................................. 9 Inspection tank for SSOV and automatic vent valve leak checking. ............................................... 17

List of Tables
Table 1. Summary of Safety Control Recommendations. .............................................................................. 2 Table 2. Safety Shutoff Valve Recommendations for Gas-fired Boilers. See Section 2.2.2.3. .................... 4 Table 3. Safety Shutoff Valve Recommendations for Oil-fired Boilers. ........................................................ 4

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Oil- and Gas-Fired Single-Burner Boilers

FM Global Property Loss Prevention Data Sheets

1.0 SCOPE This FM Global loss prevention data sheet discusses the fuel hazards inherent in gas-fired or oil-fired single-burner boilers. Recommendations are made for the installation, maintenance, and operation of combustion safeguards and boilers as related to the fuel explosion and fire hazards. Automatic and supervised manual single-burner boilers rated greater than 400,000 Btuh (117 kW) input are covered. This data sheet does not apply to natural draft boilers; refer to ASME CSD-1, Controls and Safety Devices for Automatically Fired Boilers. This data sheet also does not apply to boilers 2,500,000 Btuh (732 kW) or less that are listed by a nationally recognized testing laboratory agency. Multiple-burner boilers are covered in Data Sheet 6-5, Oil- or Gas-Fired Multiple Burner Boilers. Related data sheets are 7-32, Flammable Liquid Operations, and 7-88, Storage Tanks for Flammable Liquids. 1.1 Changes May 2006. Editorial change was made to the recommendation 2.2.4.1. 2.0 LOSS PREVENTION RECOMMENDATIONS 2.1 Introduction 2.1.1 FM Approved equipment and devices such as fuel safety shutoff valves (SSOVs), fuel and air supervisory switches, timers, and flame failure supervisory combustion safeguards, etc. should be used. Approved means equipment tested by FM Approvals and listed in the Approval Guide, a publication of FM Approvals. In a few cases, FM Approved equipment may not be available to meet a specific arrangement or particular field operating condition. In these cases, the equipment should be from a reliable manufacturer and have proven satisfactory field experience. See Table 1 for a summary of safety control recommendations. 2.1.2 Equipment and devices should be suitable for the environment in which they are installed. Equipment used in dusty or moist areas requires careful selection.
Table 1. Summary of Safety Control Recommendations. Safety Device/Control Gas-Fired Boilers Fan motor interlocks and air flow/ Yes pressure switchesforced draft, induced draft, and/or recirculation fans Pre-purge at 50 maximum airflow, Yes minimum 4-volume changes Post-purge, 15 seconds minimum Yes, if >12.5 MMBtuh (3662 kW) Igniter/pilot See Section 2.2.2 Pilot SSOV Yes Main burner SSOV Yes. See Table 2. Tightness test connections for main Yes. See Data Sheet 6-0. SSOVs Low gas pressure switch Yes, if > 2.5 MMBtuh (732 kW) High gas pressure switch Yes, if > 2.5 MMBtuh (732 kW) Interlock for low fire light-off Yes, if >2.5 MMBtuh (732 kW) Nonrecycling combustion safeguard Yes, if >2.5 MMBtuh (732 kW) 10-second pilot flame establishing period Yes Limited main flame trial-for-ignition 10 seconds SSOV proved closed prior to and during purge Low oil pressure switch High/low oil temperature switch See Table 2 Oil-Fired Boilers Yes

Yes Yes, if >2.8 MMBtuh (820 kW) See Section 2.2.2 Yes Yes. See Table 3

Yes, if >2.8 MMBtuh (820 kW) Yes, if >2.8 MMBtuh (820 kW) Yes 10 seconds for No.2 & No.4 Oil; 15 seconds for No. 5 & No.6 Oil See Table 3 Yes, if >2.8 MMBtuh (820 kW) unless oil pump is integral with burner motor shaft Yes (for heated oils)

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Safety Device/Control Atomizing steam/air switch Electric igniter proved fully inserted High steam pressure/temp. Low water cutout*
* Refer to Data Sheet 6-12, Low Water Protection.

Gas-Fired Boilers Yes (if applicable) Yes (on unattended boilers) Yes

Oil-Fired Boilers Yes (if applicable) Yes (if applicable) Yes (on unattended boilers) Yes

2.2 Equipment and Processes 2.2.1 Combustion Air and Preignition Purge 2.2.1.1 Interlock any fans for combustion air, for removal of combustion products, or for recirculation of combustion products so that fuel SSOVs are closed and electric ignition deactivated unless fans are in operation and proper flow is provided. Air flow or pressure switches should be provided. For three-phase blower motors, the airflow switch should be interlocked with the motor starter. Loss of airflow or fan motor not running should cause a complete shutdown of the boiler. Air flow supervision is not needed with oil-firing if the fan is integral with the burner motor shaft. 2.2.1.2 Design for a supervised preignition purge of the boiler furnace, passes, and horizontal breeching with air flow not less than 50% of the air flow at the maximum firing rate for a duration sufficient to achieve not less than four volume changes of the furnace/fire box and boiler passes. Flame failure or failure to ignite on start-up requires a full repurge before attempting a relight. 2.2.1.3 Interlock induced- or forced-draft dampers that are automatically positioned by the combustion control system so that on lighting off, the induced-draft dampers will be open and the forced-draft dampers will be in position for smooth light-off. Adjust the control for these dampers so that proper amounts of air for complete combustion at all firing rates will flow through the boiler furnace. Smooth light-off depends on proper draft setting and on proper throttling of the fuel input. The burner fuel and air supplies should be suitably controlled to give smooth light-off at low-fire conditions. It is preferred that low fire position switches, when they are used, be located on the controlled device in case of linkage separation. This may not be practical on some small package boilers. 2.2.1.4 If there is no ducted air supply to the boiler, provide openings or the equivalent in the boiler room to permit entrance of sufficient fresh air for complete combustion of the fuel at all firing rates. At least 1 ft2 (0.09 m2) of free opening should be provided for every 2 MMBtuh (586 kW) of fuel burned. For boilers operating with natural draft, allow 1 in2 (650 mm2) of free opening for every 2,000 Btuh (586 W) of fuel burned for boilers with horizontal stacks and 4,000 Btuh (1172 W) for boilers with vertical stacks. Some plants utilize exhaust fans to rid the area of dust or vapors. If the boiler room is not separate from these areas, the combustion air fan may not be able to overcome the negative pressures created. In such an instance, the combustion air supply should be ducted directly from out-of-doors. Air preheating may be necessary in colder climates as cold air can interfere with proper operation of a boiler, and can cause a freeze-up of pneumatic control lines. Control air should be kept clean and dry. Refer to Data Sheet 9-18/17-18, Prevention of Freeze-ups. 2.2.2 Igniters, Safety Shutoff Valves, and Combustion Safeguards 2.2.2.1 Provide igniters that have sufficiently large capacities to ensure prompt ignition of the main burners. It is preferred that igniters be used that are stable with the main burner extinguished and with maximum boiler draft. Do not use direct spark igniters on light oil burners greater than 2.8 MMBtuh (820 kW) input or gas-fired burners greater than 400,000 Btuh input unless the burner lights off at a fuel input less than these ratings. There are four classes of igniters: Class 1, 2, 3, and 3 Special. Igniters are described in Appendix C. 2.2.2.2 Install the pilot, electric-spark igniter, and flame-sensing element of the combustion safeguard securely so that the position of each in respect to the others and the main flame will not change. Provide observation ports so that the positions can easily be observed while the pilot and/or main burner are firing. These units should be readily accessible for inspection and cleaning. 2.2.2.3 Install safety shutoff valves (SSOVs) in the fuel supply lines to both the pilots and main burners. Refer to Tables 2 and 3 for SSOV recommendations. For small pilots or fuel burners having less than 400,000

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FM Global Property Loss Prevention Data Sheets

Btuh (117 kW) input, one SSOV is adequate. Using an FM Approved automatic leak detection device fulfills the requirements for proof-of-closure (as required in Table 2). This device pumps gas above line pressure between the two safety shutoff valves and monitors for pressure drop for a predetermined period of time before purge can begin. Once the test has been completed, the pressurized gas is bled back into the supply line. See Appendix C for more information on SSOVs. 2.2.2.4 Provide an FM Approved nonrecycling flame-supervisory combustion safeguard arranged to first prove the existence of a reliable pilot flame before permitting the main burner SSOV to open. Limit the pilot-trial-for-ignition period to ten seconds. When an Approved high-voltage spark igniter is provided, the fuel burning pilot and pilot trial-for-ignition may be omitted. If a retractable type of igniter is used, it should be proved to be fully inserted. After a shutdown occurs due to a flameout, the combustion safeguard is allowed to recycle once on a gas-fired boiler rated at less than 2.5 MMBtuh (732 kW) or on an oil-fired boiler rated at less than 2.8 MMBtuh (820 kW).
Table 2. Safety Shutoff Valve Recommendations for Gas-fired Boilers. See Section 2.2.2.3. 400,000 Btuh 2.5 MMBtuh (117732 kW) Two SSOVs, or one SSOV with proof-of-closure >2.55 MMBtuh (7321465 kW) Two SSOVs or one SSOV with proof-of-closure >512.5 MMBtuh (14653662 kW) Two SSOVs, one with proof-of-closure >12.5 MMBtuh (>3662 kW) Two SSOVs with proof-of-closure

Table 3. Safety Shutoff Valve Recommendations for Oil-fired Boilers. 400,000 Btuh12.5 MMBtuh (1173662 kW) Two SSOVs or one SSOV with proof-of-closure * >12.5 MMBtuh (>3662 kW) Two SSOVs with proof-of-closure *

* A relief device should be installed between valves if there is a possibility of pressure build-up due to location in a hot area.

2.2.2.5 Arrange a nonrecycling flame-supervisory combustion safeguard for direct supervision of the main burner flame only, following proof of pilot flame and opening of the main burner SSOV. Limit the main burner trial-for-ignition to the shortest practical time, but not more than ten seconds (15 seconds for No. 5 and No. 6 oil). 2.2.2.6 Install the combustion safeguard flame-sensing element(s) in accordance with the manufacturers instructions. Locate the main-burner flame-sensing element so that it reliably senses the main flame at all firing rates. The fuel SSOVs must be deenergized within four seconds of a flameout. When a pilot is proved by a combustion safeguard, supervision should be at a location where it will reliably sense the presence of a flame. A main burner should be ignited immediately by its pilot even when the pilot is reduced to the minimum flame capable of holding the flame-sensing relay of the combustion safeguard in the energized (flamepresent) position. 2.2.2.7 The safe-start check of the combustion safeguard should not be nullified by the action of operating or limit controls. A safe-start check, which takes place each time a boiler is started, determines if the flame scanner will detect a flameout. For boilers that are in continuous operation or where an operating cycle exceeds 24 hours, provide an automatic self-checking UV flame scanner (when a UV flame scanner is used). Self-checking is not needed on electronic UV scanners that do not use UV cells. 2.2.2.8 A combustion safety control system may be linked to a programmable logic controller (PLC) approved for burner management or combustion safety. The PLC may be used for boiler control such as combustion control and feedwater control, but not for any other process control. Refer to Data Sheet 7-45, Instrumentation and Control in Safety Applications. 2.2.3 Additional Safety Controls 2.2.3.1 High water temperature or steam pressure limit controls should be provided on all boilers, particularly unattended boilers. Operation of these devices should cause a safety shutdown, requiring a manual reset. 2.2.3.2 Provide interlocked low-fire lighting off on automatic boilers so that on a call for heat, and after the preignition purge has been satisfied, fuel and air controls are in the correct minimal low firing positions before the ignition cycle can proceed for gas burners greater than 2.5 MMBtuh (732 kW) and for oil burners greater than 2.8 MMBtuh (820 kW). 2.2.3.3 Provide low water protection interlocks. See Data Sheet 6-12, Low Water Protection.

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2.2.3.4 Consideration should be given to provide combustibles/oxygen analyzers, as an aid to safe and efficient operation, on supervised manually operated boilers of 100,000,000 Btuh (29,300 kW) capacity and over, and preferably on smaller units as well. 2.2.4 Additional Recommendations for Gas Firing The following recommendations apply to new boilers and new conversions to gas firing, and burner installations on any size boiler, new or in service, where a serious production interruption is possible. 2.2.4.1 Provide permanent and ready means for making periodic tightness checks of the main burner safety shutoff valve. See Data Sheet 6-0, Elements of Combustion Controls, and Safeguards in Industrial Heating Equipment. The need for tightness checks is lessened if an FM Approved automatic leak testing system is installed. This type of system pressurizes the space in between the SSOVs, and checks for pressure drop each time a boiler is started. Perform a manual leak test annually if equipped with the automatic system to determine that leakage does not exceed the requirements of Data Sheet 6-0, Elements of Combustion, Controls, and Safeguards in Industrial Heating Equipment. 2.2.4.2 Provide high and low gas pressure interlocks for boilers greater than 2.5 MMBtuh (732 kW) by means of FM Approved pressure switches arranged to shut off and lock out all fuel and electric ignition in the event of dangerously low or high pressures. Gas pressure switches are optional for boilers less than 2.5 MMBtuh (732 kW) if provided with a pilot. Setting of switches should fall within the turndown or safe operating range of the burner. Locate the switches between the pressure regulator and safety shutoff valves. Alternatively, the high pressure switch can be located downstream of the safety shutoff valves, however, account for pressure drops in the fuel train when setting the high pressure switch. The fuel train should be designed to withstand the maximum pressure that can develop because of a pressure regulator failure. The high pressure switch should be set lower than this pressure. If the fuel train cannot withstand this pressure or this pressure can exceed 60 psig, then install a relief valve just downstream of the regulator and vent to a safe location. Set the high pressure switch lower than the relief valve setting and no higher than 150% of normal pressure. Preferably, set the switch at about 125% of normal pressure as long as nuisance tripping does not result. 2.2.4.3 Provide manual gas cocks which will only allow handles to be installed such that the handle must be perpendicular to the gas pipe when closed. An example of a permissive start-up and firing sequence for a gas-fired automatically lighted boiler burner is shown in Figure 1. (See also Fig. 2.) For a supervised manual system, the permissive start and firing sequence is essentially as shown in Figure 1. The operator initiates the start of the sequence. Then, as the sequence steps are completed and the interlocks are satisfied the subsequent step may be initiated. When changes in firing rate are made manually, the fuel and air supplies should be adjusted simultaneously at a pre-established optimum air-fuel ratio. Only one control device should be manipulated to achieve the change in firing rate. 2.2.5 Additional Recommendations for Oil Firing The following recommendations apply to new boilers and new conversions to oil firing, and burner installations on any size boiler, new or in service, where a serious production interruption is possible. 2.2.5.1 Provide a low-fuel-oil supply pressure interlock by means of an Approved pressure switch arranged to shut off and lock out all fuel and electric ignition in the event of inadequate supply pressure. A low oil condition should require that an operator correct the problem and then manually reset the switch or combustion safeguard. 2.2.5.2 Provide a low-temperature interlock for oil that requires preheating to ensure that the oil is at the viscosity recommended by the burner manufacturer before the burner can be fired. A high temperature cutout switch should also be provided if the oil can be heated enough to cause vapor lock at the pump. To ensure prompt ignition during trial-for-ignition, arrange the piping and preheating system so that the volume of unheated oil immediately upstream of the burner tip is at a minimum. Specifications for oils should be understood by operators. 2.2.5.3 Interlock the atomizing air or steam supply to the burner (generally used for Nos. 5 and 6 oil) so that all fuel and electric ignition will be shut off and locked out in the event of inadequate atomizing pressure or lack of proper differential between oil pressure and atomizing medium pressure.

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Oil- and Gas-Fired Single-Burner Boilers

FM Global Property Loss Prevention Data Sheets

Fig. 1. Single-burner automatic-lighted gas-fired boiler. Example of a permissive start and firing sequence.

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FM Global Property Loss Prevention Data Sheets

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1. 2. 3. 4.

Manual Cock Pressure Regulator Low Gas Pressure Switch Safety Shutoff Valve

5. 6. 7. 8.

Safety Shutoff Valve w/Proof of Closure Leak Test Connection High Gas Pressure Switch Combustion Air Pressure Switch

Fig. 2. Schematic. Typical gas-fired piping arrangement over 2.5106 Btuh (732 kW).

An example of a permissive start-up and firing sequence for an oil-fired automatic-lighted boiler is shown in Figure 3. (See also Fig. 4.) For a supervised manual system, the permissive start and firing sequence is essentially as shown in Figure 3. The operator initiates the start of the sequence. Then, as the sequence steps are completed and the interlocks are satisfied, the subsequent steps may be initiated. When changes in firing rate are made manually, the fuel and air supplies should be adjusted simultaneously at a pre-established optimum air-fuel ratio. Only one control device should be manipulated to achieve the change in firing rate. 2.2.6 Gas-Fired Multiport Burner Grid 2.2.6.1 The recommendations previously presented in this data sheet should be applied. However, main flame supervision (with interrupted pilot) is generally impractical on gas- fired multiport burner grids. 2.2.6.2 The pilots may be either spark-ignited or manually ignited. 2.2.6.3 The light-off pilots should have FM Approved nonrecycling flame supervision combustion safeguards arranged to prove the existence of reliable pilot flame before permitting the main burner safety shutoff valve to open and during main burner operation. 2.2.6.4 Stabilization pilots should be supervised. The failure of the pilot flame should cause shutoff of the fuel to the pilots and main burners. 2.2.7 Flue Gas Recirculation Interlocks The following interlocks should be provided to prevent unstable combustion due to an FGR malfunction, and should cause a boiler shutdown and closure of the FGR damper. Otherwise, damage could result to the FGR system or conditions could result that could lead to a boiler explosion due to off-ratio firing or a flameout. 2.2.7.1 An FGR fan motor electrical interlock should be provided, using motor starter auxiliary contacts (three-phase motors only). 2.2.7.2 An FGR fan flow switch should be provided to verify proper gas flow through the system. 2.2.7.3 An FGR control damper position interlock should be provided, if practical. This compares actual damper position with control position and should not allow the boiler to operate if the damper is not within the limits. 2.2.7.4 An FGR circuit trouble interlock should be provided. The boiler should not operate if there is circuit trouble or loss of power. 2.2.7.5 A stack low temperature interlock should be provided.

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FM Global Property Loss Prevention Data Sheets

Fig. 3. Single-burner automatic-lighted oil-fired boiler. Example of a permissive start and firing sequence.

2.3 Protection 2.3.1 Provide automatic sprinklers of proper temperature rating in boiler rooms of combustible construction and in noncombustible boiler rooms that contain sufficient combustibles, other than fuel oil, to sustain a fire. Refer to Data Sheet 7-88, Storage Tanks for Flammable Liquids. 2.3.2 Locate boilers preferably in a separate noncombustible room or basement. A manufacturing room is not objectionable for small boilers if the floor area within 15 ft (4.5 m) of the burner and 10 ft (3 m) of the boiler is kept free of combustibles and the room is free from readily ignitable fibers, exposed flammable liquids, combustible dusts, or contents susceptible to smoke or fume contamination. See Section 2.2.1.4 on combustion air.

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1. 2. 3. 4. 5.

Manual Cock Preheater Low Oil Temperature Switch Low Oil Pressure Switch Oil Circulating Valve

6. Safety Shutoff Valve w/Proof of Closure 7. Safety Valve 8. Atomizing Media Pressure Switch 9. Combustion Air Pressure Switch 10. Pressure Regulator

Fig. 4. Schematic. Typical oil-fired piping arrangement over 2.5106 Btuh (732 kW).

2.3.3 Replace wooden floors with concrete extending 4 ft (1.2 m) beyond the boiler, unless there is a generous clearance for free-air circulation beneath the boiler sufficient to keep floor temperature below 160F (71C). Capping a wooden floor with concrete is not acceptable. 2.3.4 Avoid passing metal stacks through combustible ceilings, walls, and floors. Where this is unavoidable, provide metal collars, rain shields, and clearances or suitable insulation and/or clearances to keep the surface temperature of the combustible material below 160F (71C). 2.3.5 Clearance between metal stacks and stored combustible materials should be at least 30 in. (0.76 m). Guards that will assure this clearance should be installed. 2.3.6 Provide each oil- or gas-fired boiler with a manually operated fuel shutoff valve for emergency closing in case of fire. The valve should be prominently marked, easily accessible, and preferably located outside the boiler room. 2.3.7 Provide fusible-link-actuated shutoff valves in the oil supply line to oil-fired boilers. These valves should be located in the boiler room on the suction side of the pump. For multi-boiler locations with a common oil supply pump, each boiler should have its cable linked to a separate valve. The fusible link for the valves should be located at the boiler burner front. The valves should be tested periodically to be sure that the weights will close the valves. An alternative method would be to have a heat detector mounted above the burner and wired into the safety control circuit. Actuation of this device would cause the SSOV to become deenergized. 2.3.8 Recognition should be given to the fire hazards imposed by leakage or rupture of oil piping near the burner. Particular attention should be given to flexible connections, hoses, swivel joints, etc. Good housekeeping is important. Braided oil hoses should be replaced periodically according to manufacturers recommendations, and a commitment to a replacement frequency should be made based on usage and consultation with the hose or boiler manufacturer. Older hoses may not flex properly and may leak at threaded connections in the fuel piping or result in hose breakage, especially if there are 90 degree bends; hoses that are bulged, stiff, or corroded need immediate replacement. Hoses are subject to both tensile and compressive stresses, to internal pressure, and to the extremes of temperature, vibration, corrosive atmospheres, and physical impact and reactive forces. Double braided, noncombustible hoses should be used. Hoses should be designed for the oil being fired and should be capable of withstanding four times the normal maximum operating pressure. Hose couplings and fittings and minimum bending radius should be in accordance with manufacturers

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Oil- and Gas-Fired Single-Burner Boilers

FM Global Property Loss Prevention Data Sheets

instructions. If 90 degree bends are necessary, use 90 degree elbows. Valves should be installed upstream of hoses. Flexible hoses are a likely place for a fuel leak to develop, and should be examined carefully. 2.4 Operation and Maintenance 2.4.1 General 2.4.1.1 Operators should be trained in the proper operation of the boiler and in the specific functions of the various safety controls. Operating instructions should be posted or kept in the boiler room for ready reference. Posted operating procedures that are faithfully adhered to, combined with a solid operator training program that prepares operators to handle various emergency scenarios before they happen, will reduce losses. Operator awareness of critical valve positions and other conditions before taking any actions will greatly contribute to safe operation of boilers. For example, if an operator checks to see if any valves, manual and automatic, have been open before lighting off a gas burner, then the operator can determine if there is a possibility of a vapor accumulation in the combustion chamber. 2.4.1.2 Maintain all equipment in proper operating condition. Maintenance details and schedules depend on the equipment and operating conditions. The program should follow a specific routine recommended by the manufacturer and should include, at scheduled intervals, maintenance of burner equipment, gas SSOV leakage testing, inspection and cleaning of the electric-igniter and/or pilot-burner assembly, adjustment of linkages and controllers for fuel-air ratio control dampers and valves, and maintenance and testing of combustion safeguards and safety controls as recommended by the manufacturer. SSOVs should be inspected and maintained according to manufacturers instructions. Valve stems and guides should be kept clean to prevent sticking. Certain soft parts such as packing, seals, and O-rings may harden with time, and should be replaced as necessary. Aging valves that have not been maintained may need to be replaced. 2.4.1.3 Inspect and test safety controls periodically according to manufacturers recommendations to ensure proper functioning when emergencies arise. Failure to make periodic checks may result in fire or explosion damage and may also contribute to accidental shutdown and loss of production. A carefully planned inspection/test procedure should be drawn up for each boiler. This procedure should include tests, performed at prescribed intervals, for tightness of gas safety shutoff valves (SSOVs), for response to flame failure, and for proper action of fuel-air interlocks. Tests should be recorded on a safety-control inspection and testing report, listing the date, controls tested, their condition, and the proper sequence and methods of performing the tests. Refer to Data Sheet 9-0, Preventive Maintenance. The tests should be conducted by well-trained personnel who are familiar with the equipment and the specific functions of the various safety controls. Any defects found should be corrected immediately. Upon completion, covers of all safety controls should be secured in place to minimize tampering and introduction of dust and dirt. The following is a testing frequency schedule which should be followed whenever practical. Details of the testing procedures should be developed in accordance with manufacturers recommendations if available. 1. Monthly. a. Flame failure detection system. b. Fan and airflow interlocks. c. Fuel safety shutoff valves for leakage. Refer to Data Sheet 6-0, Elements of Industrial Heating Equipment. d. Low fire start interlock. e. High steam pressure or temperature interlock. f. For Oil: Fuel pressure and temperature interlocks.

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g. For Gas: (a) Gas cleaner and drip leg. (b) High and low fuel pressure interlocks. Note: Monthly and semiannual tests should be performed if qualified personnel who regularly maintain burner equipment are available. Otherwise, these tests may be performed annually by a qualified contractor. 2. Semiannually or Annually (if conditions permit). a. Igniter and burner components. Smooth, reliable light-off in the required period of time should be achieved. Proper flame color and shape and exhaust color are indicative of good combustion. b. Combustion air supply system. Air flow or pressure switches, and damper high/low fire interlocks should be checked. c. Flame failure system components. Flame scanners and all safety controls that interlock with the SSOV through the combustion safeguard controller should be checked. d. Piping, hoses, wiring, and electrical connections of all interlocks and shutoff valves. Check for leaks, corrosion, and loose connections. e. Combustion control system. Check the fuel-air control system at various loads to see that proper air-fuel stoichiometry is maintained during turndown. f. Calibration of indication and recording instruments. 3. As Required for Oil-Firing. a. Disassemble and clean atomizers. b. Clean strainers. Cleaning of fuel piping and provision of strainers or cleaners in the fuel supply will prevent foreign matter from interfering with the operation of valves. 2.4.2 Alternate and Simultaneous Fuel Systems 2.4.2.1 Alternate Fuel Firing and Transfer System Some single-burner boilers may fire either gas or oil. The combustion control system is arranged to provide a proper fuel-air ratio for individual firing of either fuel, but only one fuel at a time. The transfer to the alternate fuel may be accomplished either manually or automatically through a suitable fuel transfer system. The various interlocks, flame supervision, and safety shutoff valves should be in service for the fuel being fired. The transfer procedure should be compatible with the specific combustion control system and should include the following sequence: (1) the burner should be shut down; (2) the alternate fuel system with its respective interlocks and the combustion control system adjusted for the alternate fuel should be placed in service; and (3) a light-off procedure compatible for the fuel should be followed. These procedures should be followed when switching to other fuels such as propane. Never change over in a high firing position. If simultaneous transfer is necessary, the boiler must be reduced to low firing. 2.4.2.2 Alternate Fuel SystemSimultaneous Fuel Firing Transfer Some steam demands may require transfer from firing one fuel to another without stopping the fuel input to the furnace even though the combustion control system is suitable for firing only one fuel at a time. The transfer procedure should be accomplished manually by a qualified operator following a procedure that will prevent a fuel-rich condition. The burner should be capable of burning two fuels simultaneously and the system should be equipped with the various interlocks, flame supervision, and SSOVs necessary for the combustion safe guard system for each fuel. The fuel selector switch should be provided with a gas position in which oil cannot be fired, an oil position on which gas cannot be fired, and a gas-oil position that permits simultaneous firing of both fuels provided all interlocks for both fuels are satisfied, including light-off position for both fuels. Manual valves should be provided at the burner, downstream of the SSOVs in each fuel line. Pressure gauges should be installed downstream of the manual valves.

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2.4.2.2.1 Procedure for changing from gas to oil 1. If an intermittent pilot is available, place it in service. 2. Check that the manual oil valve at the burner is closed. 3. Establish oil fuel system to satisfy interlocks. 4. Install oil atomizer. 5. Open atomizing medium shutoff valve. 6. Place combustion control system in manual position. 7. Reduce gas flow to the low firing rate. 8. Place oil control valve in the normal light-off position. 9. Place fuel transfer switching system into oil-gas position. If the oil safety interlocks are satisfied, the oil safety shutoff valve will open. Fuel oil pressure now will be upstream of manual oil valve at the burner. 10. Observe the gas pressure downstream from the manual gas shutoff valve and slowly close valve until the gas pressure starts to drop. At this point, the gas flow rate is controlled by the manual valve instead of by the normal control valve. 11. Simultaneously and slowly close the manual gas valve while operating the manual oil valve to light the oil flame from the gas flame. Continue to increase the oil firing rate while cutting back on gas firing rate to keep a constant heat input of the combined fuels to the burner until the manual gas valve is closed and manual oil valve is fully open. Care must be taken to maintain an adequate amount of excess air at all times by continuously observing the burner flame, or by observing the fuel-air ratio or oxygen indicator, if provided. During this period, air flow is maintained at a constant rate, with only the manual fuel valves in operation. 12. Place the fuel transfer system in the oil position. The gas safety shutoff valves will now close. 13. Return the combustion control system and burner firing rate to normal operation. 2.4.2.2.2 Procedure for changing from oil to gas 1. If an intermittent igniter is available, place it in service. 2. Check that the manual gas valve at the burner is closed. 3. Establish gas fuel system to satisfy interlocks. 4. Place combustion control system in manual position. 5. Reduce oil flow to the low firing rate. 6. Place gas control valve in the normal light-off position. 7. Place fuel transfer switching system in the gas-oil position. If the gas safety interlocks are satisfied, the gas safety shutoff valves will open. Gas pressure now will be upstream of gas manual valve at the burner. 8. Observe the oil pressure downstream from the manual oil shutoff valve and slowly close valve until the oil pressure starts to drop. At this point, the oil flow is controlled by the manual valve instead of by the normal control valve. 9. Simultaneously and slowly close the manual oil valve while operating the manual gas valve to light the gas flame from the oil flame. Continue to increase the gas firing rate while cutting back on oil firing rate to keep a constant heat input of the combined fuel to the burner until the oil valve is closed and manual gas valve is fully open. Care must be taken to maintain an adequate amount of excess air at all times by continuously observing the burner flame, or by observing the fuel air ratio or oxygen indicator, if provided. During this period, air flow is being maintained at a constant rate, with only the manual fuel valves in operation. 10. Place the fuel transfer system in the gas position. The oil safety shutoff valve will now close. 11. Return the combustion control system and burner firing rate to normal operation.

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2.4.2.3 Simultaneous Firing of Oil and Gas Some single-burner assemblies and combustion control systems that maintain a proper fuel-air ratio for each fuel and the combined fuel input are suitable for simultaneous firing of oil and gas. The combustion control system should be of the type that meters and totals to inputs from both gas and oil fuels, alone or in any combination, and controls air flow proportionally. In most instances, a fuel selector switch is provided to permit firing of either fuel or both fuels simultaneously. The various interlocks, flame supervision and SSOVs should remain in service for the fuel or fuels being fired. During simultaneous firing of two fuels, the interlocks for one fuel should not bypass the interlocks for the second fuel. Such a bypass could permit the introduction of the second fuel in a condition unsuitable for proper combustion. The operating procedures should be compatible with the specific combustion control system and should follow the manufacturers instructions. 2.4.3 Flue Gas Recirculation 2.4.3.1 Design Considerations 2.4.3.1.1 The flue gas recirculation (FGR) fan, which delivers flue gas back to the burner for the purpose of NOx reduction, should be sized to deliver the correct volume of gas at the required pressure. 2.4.3.1.2 A gas/oil selector switch should be provided for combination-fired boilers to change recirculation rates. The rates are lower for oil than for gas. 2.4.3.1.3 Allow a cool-down period (allowing the fan to run) for the FGR fan after boiler or FGR shutdown, if practical. 2.4.3.2 Fan-Assisted FGR System 2.4.3.2.1 The FGR control damper should be proven fully open before purge can begin. This permits air flow from the forced draft fan through the FGR system and out the stack. 2.4.3.2.2 The FGR control damper should close after purge and be proven fully closed before light-off. 2.4.3.2.3 The FGR fan should start after burner light-off. 2.4.3.2.4 The FGR damper should not be allowed to open until the stack temperature reaches a predetermined value established by the manufacturer. If the gas temperature is too low, the percentage of gas recirculated will be too high since the system controls volumetric flow rather than mass flow. 2.4.3.2.5 A minimum time delay established by the manufacturer after proper stack gas temperature is established should be allowed before the FGR damper is permitted to open to the low fire position. 2.4.3.2.6 A minimum time delay established by the manufacturer after initial FGR damper opening should be allowed before the boiler is permitted to modulate in order to achieve steady state operation. Note: It is preferable to purge the FGR duct and start up the system as recommended in this section; however, this may not be possible with some systems. Some systems have all of the fans starting at the same time. The FGR damper may also be mechanically connected to the fuel and air controls, making it impossible to implement some of these recommendations. When the above procedure cannot be followed, purge time should be of sufficient duration consistent with the above procedure to ensure that only an inconsequential amount of combustibles are present at the end of the purge taking into account the recirculation through the FGR duct. 2.4.3.3 Induced Flue Gas Recirculation 2.4.3.3.1 The flue gas recirculation damper should modulate according to the firing rate. The combustion controls should be designed and tested to ensure that the rate of change of FGR flow matches the fuel and air flows, with the flue gas recirculation matching the fuel in the lead-lag control arrangement if possible. This can be accomplished by means of a direct mechanical linkage to the fuel-air controller or by other control means such as electric or pneumatic. Controls should be evaluated for reliability. The damper should be designed to fail in the closed position if there is an actuator failure, linkage failure or loss of actuating medium. A fixed damper (positioned at initial startup) could allow combustion upset to occur during transient conditions or load changes due to a lag in pressure changes throughout the system, causing a temporary unacceptable increase in the rate of recirculation. It is preferable that fixed dampers not be used in new installations. If a fixed damper is used, operators should understand that rapid load changes could cause flame instability.

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2.4.3.3.2 Purge time should be re-evaluated to account for purging the flue gas recirculation duct. Since a percentage of purge air will be recirculated, the purge period will have to be increased in order to purge to four volume changes. 2.4.3.3.3 Methods to reduce NOx can cause an increase in other emissions such as carbon monoxide (CO) and unburned hydrocarbons. It should be verified that CO emissions remain well below the lower explosive limit at all steady state loads and during load changes. With a properly designed and maintained system, CO emissions may actually decrease. 2.4.3.3.4 Operating at very low or high loads may cause combustion instability when using some NOx reduction methods, especially when using secondary combustion or low NOx burners. Turndown ratio may need to be reduced slightly when using these methods. At low loads, although mixing and turbulence may be assisted by FGR, too much flame quenching may cause an increase in unburned combustibles. Systems with fixed damper systems may be more susceptible to this. At high loads, the fuel-air velocity may overcome the flame velocity and cause it to move away from the burner and become unstable. Flame scanners may need to be relocated if flame characteristics change. 2.4.3.3.5 Maximum recirculation rates should be approximately 30% for natural gas and 15% for oil. Flue gas recirculation is primarily used to reduce thermally generated NOx and is not always as effective for oil because oils generally contain more fuel-bound nitrogen than natural gas. 2.4.3.3.6 When installation of flue gas recirculation is planned, calculations should be provided that explain the percentage of recirculated flue gas in terms of mass flow rates. The rate of recirculation is equal to the mass flow of recirculated gas divided by the total of the air, fuel and recirculated gas mass flow rates. A mechanical and thermal energy balance should be calculated to verify the percentage flue gas mass flow if it is impractical to measure it. 2.4.3.3.7 If flue gas is allowed to recirculate at start-up, it will be at a lower temperature than the normal operating temperature. Since the system is controlled volumetrically, there will be a slightly higher mass flow rate when the flue gas is cold. Too much FGR at start-up when the furnace is cold and before a stable flame is established could cause combustion difficulties. Therefore, it should be verified by calculation that the increased flue gas density of cold flue gas does not adversely impact the combustion fuel-air ratio during start-up. The percentage of recirculation at start-up may need to be reduced. 2.4.3.3.8 During installation, setup of the system (such as damper linkage adjustments and cam settings) should be verified to be in agreement with calculations by means of on-site testing performed under the direction of the manufacturer. 2.5 Electrical 2.5.1 Electrical installations should conform to the National Electrical Code or other statutory local codes. The burner front is classified as non-hazardous. Although there is a possibility of combustible vapors being present, the close proximity of the igniter, pilot, and burner make the additional risk of an explosion from an electrical spark negligible. 2.5.2 AC and dc safety-control circuits should be two-wire, one side grounded, and not over nominal 120 volts. All safety-control switching should be in the ungrounded conductor. If a boiler has a 240 volt safety control system, it should be determined if the SSOV coil drops out at about 175 volts. Failure of the coil to drop out at 175 volts could cause the valve to remain open all the time under fault conditions. This recommendation only applies to countries where 120 volt circuits are used and is mandatory in the U.S. Overcurrent protection should be provided. Ground fault protection is also desirable. In addition to circuit grounds, non-currentcarrying metal parts, such as equipment enclosures and conduit, should also be grounded. 2.5.3 Where an ungrounded dc power supply cannot be avoided, all switching should be located in one conductor, and ground fault detection should be provided. 3.0 SUPPORT FOR RECOMMENDATIONS Although losses during normal boiler operation due to malfunction of equipment are common, properly installed and maintained safety controls will help to prevent or mitigate many of these losses. Safety controls will also help to ensure a safe lightoff and shutdown. Note that some of the worst losses have occurred after shutdown because of gas leaking in. This shows the importance of testing safety shutoff valves. Operator

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training and following documented, safe operating procedures have also proved to be critical. The recommendations in this data sheet support the need for safety devices, operator training, proper operating procedures, regular testing and maintenance. 4.0 REFERENCES For more information, please refer to the following data sheets as cited in the text. 4.1 FM Global Data Data Data Data Data Data Data Data Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet 6-0, Elements of Industrial Heating Equipment 6-5, Oil- or Gas-Fired Multiple Burner Boilers 6-12, Low Water Protection 7-32, Flammable Liquid Operations 7-45, Instrumentation and Control in Safety Applications 7-88, Storage Tanks For Flammable Liquids 9-0/17-0, Maintenance and Inspection 9-18/17-18, Prevention of Freeze-ups

4.2 NFPA Standards NFPA 54, Installation of Gas AppliancesGas Piping NFPA 8501, Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler-Furnaces 4.2 Other Standards ASME CSD-1, Controls and Safety Devices for Automatically Fired Boilers APPENDIX A GLOSSARY OF TERMS continuous igniter: An igniter that is in operation at the completion of the igniter trial-for-ignition and remains in operation through the main burner trial-for-ignition and during the entire operating cycle of the main burner until it is shut down. (Defined as intermittent in ASME CSD-1.) intermittent igniter: An igniter that is in operation at the completion of the igniter trial-for-ignition and remains in operation through the main burner trial-for-ignition. It may, but does not have to, remain in operation for all or part of the normal operating cycle of the main burner. (No equivalent definition exists in ASME CSD-1.) interrupted igniter: An igniter that is in operation at the completion of the igniter trial-for-ignition and remains in operation through the main burner trial-for-ignition. It may not be placed in service during the normal operating cycle of the main burner. APPENDIX B DOCUMENT REVISION HISTORY May 2005. Recommendation 2.2.1.2 uses revised editorial changes to section C.3, other standards were made. January 2003. Loss information in section 3.0 was revised. September 2002. Clarification was made to Recommendation 2.2.2.1. September 2001. A change was made to Recommendation 2.2.1.1. January 2001. The following changes were made: 1. Recommendation on igniters changed to limit size of gas and light oil burners using spark igniters (2.2.2.1). 2. Recommendations on safety shutoff valves changed to state that using an Approved automatic leak detection device fulfills requirements for proof-of-closure, but does not eliminate the need for manual leak testing (2.2.2.3, 2.2.4.1). 3. Recommendation for self-checking UV flame scanners changed to state electronic UV scanners do not need self-checking (2.2.2.7).

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4. Recommendation on PLCs used for safety control changed to state that a combustion safety control system can be linked to a PLC approved for burner management or combustion safety (2.2.2.8). 5. Recommendations on gas pressure switch settings revised, and recommendation on the need for a gas pressure relief valve added (2.2.4.2). 6. A recommendation on induced flue gas recirculation was revised to add a warning on the use of fixed dampers (2.4.3.3.1). January 2000. This document was reorganized to provide a consistent format. APPENDIX C SUPPLEMENTAL INFORMATION C.1 Igniters An igniter is a fixed device which provides the energy required to ensure prompt ignition of the main burner. A pilot is a fuel-fired type of igniter. NFPA 8501, Prevention of Furnace Explosions in Fuel Oil and Natural Gas-Fired Single Burner Boiler-Furnaces, and ASME CSD-1, Controls and Safety Devices for Automatically Fired Boilers, define continuous and intermittent igniters/pilots differently. ASME CSD-1 considers a continuous pilot to be a constant burning pilot which remains lit all of the time and an intermittent pilot to be one which remains lit only while the main burner is in operation. NFPA 8501 and this Data Sheet use the definitions for igniters found in Appendix A. There are four classes of igniters; Class 1, 2, 3, and 3 Special, defined as follows: Class 1 provides energy generally in excess of 10% of burner fuel input, and should reliably ignite any combination of fuel and air under any light-off condition. Flame supervision of the igniter should be done in a manner that ensures that when flame is detected, it is of sufficient size and location to reliably ignite the main burner during all operating and transient conditions. Class 1 igniters can be operated as continuous, intermittent or interrupted igniters. Flame supervision of the main burner is not required when a Class 1 continuous igniter is used. Class 2 igniters provide energy generally between four and ten percent of burner fuel input, and should reliably ignite fuel under normal light-off conditions. A Class 2 igniter can be operated as an intermittent or an interrupted igniter. When used as an intermittent igniter to support ignition under low load and to support ignition under low load and other normal conditions, independent supervision of the main burner flame is required (at least two flame scanners). Class 3 igniters generally provide energy less than four percent of burner fuel input, and should reliably ignite fuel under normal light-off conditions. This type of igniter can only be operated as an interrupted pilot and must shut off when the main burner trial-for-ignition is ended. Class 3 Special (electric igniter) is a high-voltage igniter which will directly light-off the main burner fuel. Power should be interrupted when the main burner trial-for-ignition is ended. If the igniter is a retractable type, it should be interlocked to be proven fully inserted prior to energization. C.2 Safety Shutoff Valves Various types of SSOVs are FM Approved. Pneumatically operated valves can be used, although these are slower closing valves and must have vents sized properly in order to close as quickly as possible without damaging valve seats. There are quick-acting solenoid-operated valves that are normally used as pilot SSOVs or as second main SSOVs. Hydraulically-operated SSOVs are quite commonly used as main SSOVs: these valves employ a solenoid and a hydraulic actuator and are slow opening and quick closing. Some SSOVs are electrically operated, but also must be latched in manually to open the valve. There are also valves available with a proof-of-closure interlock using valve seal overtravel: the valve must be proven closed before the purge and ignition cycles can begin. This type of SSOV is required on boilers above a certain size (see Tables 2 and 3). SSOVs should be fully closed within one second after deenergization. A five-second closing time is allowed if the boiler is rated at less than 2.5 MMBtuh (732 kW); however, one second is preferred. A method for checking gas leaks with this type of arrangement would be to install the vent line to a tank partially filled with glycerine (see Fig. 5). The vent line should enter the top of the tank and terminate inside below the fluid surface. The area above the surface should be vented to a safe location out-of-doors. Operators or maintenance personnel should inspect the tank during their rounds to determine if there is a gas leak by checking for bubbles in the tank. This method would provide a continuous leak test of the upstream

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SSOV during boiler shutdown. This would also provide a means to check for a vent valve leak during firing. Checking this inspection tank should be a part of the posted start-up procedures for the boiler.

Fig. 5. Inspection tank for SSOV and automatic vent valve leak checking.

C.3 Other Standards Small oil- or gas-fired boilers are covered by NFPA 54, Installation of Gas AppliancesGas Piping. There are no known conflicts with FM Global standards. Medium (>400,000 Btuh [117 kW]) oil- or gas-fired boilers are covered by ASME CSD-1, Controls and Safety Devices For Automatically Fired Boilers. There are no known conflicts with FM Global standards. Large (>12,500,000 Btuh [3662 kW]) oil- or gas-fired single- burner boilers are covered by Chapters 1-5 of NFPA 85, Boiler and Combustion System Hazards Code (2004 Edition). NFPA 85 applies to firetube and watertube boilers having a capacity equal to or greater than 12,500,000 Btuh (3662 kW), 10,000 lb/hr (4,500 kg/hr). FM Global exceptions and comments are as follows: a. Article 5.5.2.6.1 and 5.5.4.2.1 The purge air flow rate and air change quantity should be sufficient to scavenge all gas vapor accumulations. Flow ratios and quantities which are greater than the FM Globals recommended minimum may be used. NFPA recommends eight volume air changes at 70% air flow for watertube boilers and four volume air changes at 70% air flow for firetube boilers. b. Article 5.5.2.6.8, 5.5.4.2.6, 5.6.2 and 5.7.2 Safety shutdown and nonrecycle lockout on power failure are not considered necessary when the programming control automatically recycles to the prepurge sequence after power is restored. NFPA calls for a manual reset on any interlock shutdown. c. Appendix Typical Schematic Arrangement of Safety Equipment shows the gas pilot piping with two safety shutoff valves (A), with a vent valve (C) between. Some users, manufacturers, and authorities having jurisdiction prefer this arrangement for the gas pilot piping.

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