Rockford Combustion Solutions Training Handouts

Industrial Combustion Safety Solutions
Training Handout
Combustion Solutions
1-800-922-7533 | www.rockfordsystems.com

NFPA 85 (2019 EDITION) – BOILER AND COMBUSTION SYSTEMS HAZARD CODE
4.4.3.1
Operator Training
4.4.3.2
Maintenance Training
4.4.3.1.1
4.4.3.1.2
4.4.3.1.2.1
4.4.3.1.2.2
4.4.3.1.2.3
4.4.3.1.3
The owner or the owner’s representative shall
be responsible for establishing a formal training
program that is consistent with the type of
equipment and hazards involved to prepare
personnel to operate equipment.
Operating procedures shall be established that
cover normal and emergency conditions.
Start-up, shutdown, and lockout procedures
shall all be covered in detail.
Where different modes of operation are
possible, procedures shall be prepared for each
operating mode.
Procedures also shall be prepared for switching
from one mode to another.
The owner or owner’s representative shall verify
that operators are trained and competent to
operate the equipment under all conditions prior
to their operation of such equipment.
4.4.3.2.1
4.4.3.2.2
4.4.3.2.3
4.4.3.2.4
The owner or owner’s representative shall
be responsible for establishing a formal
and ongoing program, consistent with the
equipment and hazards involved, for training
maintenance personnel to perform all required
maintenance tasks.
Maintenance procedures and their associated
training programs shall be established to cover
routine and special techniques.
Environmental factors such as temperature, dusts,
contaminated or oxygen-deficient atmospheres,
internal pressures, and limited access or confined
space requirements shall be included in the
maintenance procedures.
Maintenance procedures shall be consistent
with safety requirements and the manufacturer’s
recommendations and shall be kept current with
changes in equipment and personnel.
4.4.3.1.4
The owner or owner’s representative shall be
responsible for retraining operators, including
reviewing their competence, at intervals
determined by the owner.
4.4.3.1.5
The training program and operating and
maintenance manuals shall be kept current
with changes in equipment and operating
procedures and shall be available for reference
and use at all times.
4.4.3.1.6
Operating procedures shall be directly
applicable to the equipment involved and shall
be consistent with safety requirements and the
manufacturer’s recommendations.
2

COMBUSTION SOLUTIONS TRAINING
ASME CSD-1 AND NFPA 85 TESTING REQUIREMENTS
ASME CSD-1 (2015 Edition)
Applies to boilers up to 12,499,000 Btu/hour
CM-110
Operability and set points on all devices, where applicable, shall be verified by periodic testing, and the results shall be recorded in a boiler
log, maintenance record, service invoice, or other written record.
NFPA 85 (2019 Edition)
Applies to boilers 12,500,000 Btu/hour and greater
Fundamentals
4.4.1.3 Operation, set points, and adjustments shall be verified by testing at specified intervals, and the results shall be documented.
Single Burner
5.4.2.7.2 Manual valve leakage tests of the main safety shutoff valves shall be conducted at least annually.
Multiple Burner
6.4.1.1.3 Testing and maintenance shall be performed to keep the interlock system functioning as designed.
Typical Interlocks and Safety Devices to Be Tested:
The table below is a list of the common interlocks that are referenced throughout ASME CSD-1 and NFPA 85 which would fall under the
annual testing requirement for boilers.
TABLE A: COMMON STANDARD INTERLOCKS TO TEST
Fuel Train - Burner Motor Starter Contact Relays Boiler Interlocks
1 Low Gas/Oil Pressure 20 Combustion Air Fan 33 Purge Air Proving
2 High Gas/Oil Pressure 21 Induced Draft Fan 34 Minimum Combustion Air
3 Pilot Low Gas Pressure 35 Low Fire Proving
4 Pilot High Gas Pressure Burner Management Logic 36 High Fire Proving
5 Valve Tightness Tests (Gas/Oil) 22 Purge Time 37 Operating Steam Pressure
6 Main Gas Shutoff Valve 23 Pilot Trail for Ignition 38 Excess Steam Pressure
7 Safety Shutoff Valve 24 Main Trail for Ignition 39 Instrument Air
8 Vent Valve (Oil N/A) 25 Pilot Spark Pick-up 40 Low Furnace Pressure
9 Blocking Valve 26 Burner Position Switches 41 High Furnace Pressure
10 Downstream Manual Valve 27 Post-Purge Time 42 Operating Temperature
11 Pilot Manual Gas Shutoff Valve 28 Burner Stop 43 Excess Temperature Limit
12 Pilot Safety Shutoff Valve 29 Emergency Stop 44 Low Water Alarm
13 Pilot Vent Valve 45 Low Water Cutout
14 Pilot Blocking Valve Fuel Oil Specific 46 Aux. Low Water Cutout
15 SSOV Slow Closure (Gas/Oil) 30 Atomizing Media Pressure 47 High Water Alarm
16 BV Slow Closure (Gas/Oil) 31 Low Oil Temperature 48 High Water Cutout
17 Proof of Closure–SSOV (Gas/Oil) 32 High Oil Temperature 49 Flow Proving Switch
18 Proof of Closure – BV (Gas/Oil)
19 Flame Sensing
3

GAS PIPING CORROSION QUESTIONS TO ASK
1. Is our underground piping system coated?
2. When was our underground carbon steel piping system installed?
3. Is the underground carbon steel piping insulated from above- ground piping?
4. Is underground carbon steel piping system currently being cathodically protected?
5. Is the cathodic protection system being monitored?
*NFPA 54, 2018 Edition 7.1.3.3 Cathodic protection systems shall be monitored by testing and the results shall be documented.
6. Does our natural gas piping system have an accurate map or drawing?
7. Do we have a maintenance program for our exposed steel gas piping?
8. Do we have any atmospheric corrosion on our exposed steel gas piping?
9. When was the last time we had a Gas Leakage Detection Survey conducted on our facilities underground piping systems?
10. What loss of production and revenue would we sustain if fuel gas supply was interrupted for one day? One week?
11. Has the Natural Gas Piping Facility Isolation Valve and Building Isolation Valve been labeled and function properly?
4

COMBUSTION SOLUTIONS TRAINING
“15 MINUTES COULD SAVE A LIFE”
REMEMBER: LOOK, LISTEN & FEEL YOUR SYSTEMS!
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 a “Best Practice” 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.
A. Review control panel lights, markings and internal wiring.
Look for jumpers across terminals and relays that may be blocked & jammed open.
B. Review all safety interlock switch settings to make sure they appear reasonable (as per marked settings).
C. Verify all Main & Pilot Fuel Train 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. Verify all sensing lines to interlock switches, ratio regulators and other devices are connected.’
E. Verify that all firebox and or access doors to combustion chamber or furnace or oven chamber making 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. Verify if purge fans are moving air.
G. Review the exhaust system fans, dampers, linkage and related components.
H. Locate the termination of each vent/bleed line.
Review for gas flow and insect/bird nests (or other type of blockage such as ice, snow, etc.).
I. Verify time settings on all purge timers.
J. Do a no fuel ignition sequence (Close GV2) if possible, to verify that BMS sequences properly.
5

HONEYWELL S7800 BMS TROUBLESHOOTING FAULT LIST EXAMPLE
FAULT 1 *NO PURGE CARD* FAULT 28 *PILOT FLAME FAIL*
FAULT 2 *AC FREQ. NOISE* FAULT 29 *LOCKOUT ILK*
FAULT 3 *AC LINE DROPOUT* FAULT 30 *RUNNING ILK*
FAULT 4 *AC FREQUENCY* FAULT 31 *LOW FIRE SW. OFF*
FAULT 5 *LOW LINE VOLT* FAULT 32 *AIRFLOW SWITCH*
FAULT 6 *PURGE CARD ERROR* FAULT 33 *PREIGNITION ILK*
FAULT 7 *FLAME AMPLIFIER* FAULT 34 *CONTROL ON*
FAULT 8 *FLAME AMP/SHUTR* FAULT 35-40 *INTERNAL FAULT*
FAULT 9 *FLAME DETECTED* FAULT 41 *MAIN VALVE ON*
FAULT 10 *PREIGNITION ILK* FAULT 42 *PILOT VALVE 1 ON*
FAULT 11 *RUNNING ILK ON* FAULT 43 *IGNITION ON*
FAULT 12 *LOCKOUT ILK ON* FAULT 44 *PILOT VALVE 2 ON*
FAULT 13 *AIRFLOW SW. ON* FAULT 45 *LOW FIRE SW. OFF*
FAULT 14 *HIGH FIRE SW.* FAULT 46 *FLAME AMP TYPE*
FAULT 15 *FLAME DETECTED* FAULT 47 *JUMPERS CHANGED*
FAULT 16 *FLAME-OUT TIMER* FAULT 48 *DELAYED MV ON*
FAULT 17 *MAIN FLAME FAIL* FAULT 49 *MAN-OPEN SW. ON*
FAULT 18 *FLAME DETECTED* FAULT 50 *JUMPERS WRONG*
FAULT 19 *MAIN FLAME IGN.* FAULT 51 *FLAME TOO STRONG*
FAULT 20 *LOW FIRE SW. OFF* FAULT 52-70 *INTERNAL FAULT*
FAULT 21 *RUNNING ILK* FAULT 71-75 *DEVICE SPECIFIC*
FAULT 22 *LOCKOUT ILK* FAULT 76-93 *ACCESSORY FAULT*
FAULT 23 *AIRFLOW SWITCH* FAULT 94-108 *INTERNAL FAULT*
FAULT 24-25 *INTERNAL FAULT* FAULT 109 *INTERNAL FAULT*
FAULT 26
FAULT 27
*MAN-OPEN SW. OFF*
*START SWITCH ON*
FAULT 110-127
*INTERNAL FAULT*
6

COMBUSTION SOLUTIONS TRAINING
NFPA 86 TRAINING REQUIREMENTS
NFPA 86 (2019 Edition) – Standard for Ovens and Furnaces
7.2.1*
7.2.2
7.2.3
7.2.4
7.2.5
Personnel who operate, maintain, or supervise the furnace shall be thoroughly instructed and trained in their respective job functions
under the direction of a qualified person (s).
Personnel who operate, maintain, or supervise the furnace shall be required to demonstrate an understanding of the equipment, its
operation, and practice of safe operating procedures in their respective job functions.
Personnel 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 functions.
The training shall cover startup, shutdown, and lockout procedures in detail.
The training program shall be kept current with changes in equipment and operating procedures, and training materials shall be
available for reference.
NFPA 86 TESTING REQUIREMENTS
NFPA 86 (2019 Edition)
7.4.4
7.4.5*
7.4.6
7.4.9*
7.4.12*
7.4.18
All safety interlocks shall be tested for function at least annually.
The set point of temperature, pressure, or flow devices used as safety interlocks shall be verified at least annually.
Safety device testing shall be documented at least annually.
Valve seat leakage testing of safety shutoff valves and valve proving systems shall be performed in accordance with the
manufacturer’s instructions. 7.4.9.1 Testing frequency shall be at least annually.
Lubricated manual shutoff valves shall be lubricated and subsequently leak tested for valve closure at least annually.
An inspection shall be completed at least annually to verify that all designed safety interlocks are present and have not been
bypassed or rendered ineffective.
7

Interlocks and Safety Devices to Be Tested:
The table below is a list of the common interlocks that are referenced throughout NFPA 86 which would fall under the annual testing requirement
for a single zone oven or furnace with a single burner.
TABLE A: NFPA 86 - STANDARD INTERLOCKS TO TEST
Gas Train – Burner Motor Starter Contact Relays Oven Interlocks
1 Low Gas Pressure 21 Ventilating Fan Interlock 33 Purge Air Proving
2 High Gas Pressure 22 Combustion Air Fan 34 Minimum Combustion Air
3 Pilot Low Gas Pressure 23 Exhaust Fan 35 Low Fire Proving
4 Pilot High Gas Pressure 24 Recirculation Fan 36 High Fire Proving
5 Tightness Tests 37 Operating Temperature
6 Main Gas Shutoff Valve Burner Management Logic 38 Excess Temperature Limit
7 Safety Shutoff Valve 25 Purge Time 39 Instrument Air
8 Vent Valve 26 Pilot Trail For Ignition 40 Low Furnace Pressure
9 Blocking Valve 27 Main Trail For Ignition 41 High Furnace Pressure
10 Downstream Manual Valve 28 Pilot Spark Pick-up 42 Cooling Water Interlock
11 Pilot Manual Gas Shutoff Valve 29 Door Switches (Purge/Light-off)
12 Pilot Safety Shutoff Valve 30 Post-Purge Time
13 Pilot Vent Valve 31 Burner Stop
14 Pilot Blocking Valve 32 Emergency Stop
15 SSOV Slow Closure
16 BV Slow Closure
17 Proof of Closure - SSOV
18 Proof of Closure - BV
19 1400°F Bypass Interlock
20 Flame Sensing
8

COMBUSTION SOLUTIONS TRAINING
NOTES
9

5795 Logistics Parkway, Rockford, Illinois 61109 United States
1-800-922-7533 | 815-874-7891
RSCTH-10/2020