Table of Contents
Foreword xiii
Preface xv
1 What You Don’t Know Can Kill You 1
1.1 Knowledge Gaps in Operating Fuel Systems and Combustion Equipment / 4
1.2 Managing Fuel Systems and Combustion Equipment Risks / 6
1.3 The Creation of Fuel Systems and Combustion Equipment Codes and Standards / 8
1.4 Fuel System Codes and Standards / 11
1.5 Combustion Equipment Codes and Standards / 12
1.6 Other Widely Recognized Code- and Standards-Related Organizations / 13
1.7 Safety Instrumented Systems and Safety Integrity Levels / 15
1.8 The World of Insurance and Combustion Equipment / 17
1.9 Personal Criminal Liability / 20
Notes and References / 22
2 Combustion Basics 23
2.1 Combustion Defined / 24
2.2 Fuels / 25
2.3 Heat/Ignition / 29
2.4 Oxygen/Air / 29
2.5 Combustion Chemistry / 31
2.6 Environmental Emission Issues / 33
2.7 Basic Burner Design Issues / 35
2.8 Draft Systems / 37
2.9 Understanding and Evaluating Flames / 42
2.10 Fuel/Air Ratio Evaluations / 47
Notes and References / 51
3 Natural Gas Piping Basics 53
3.1 Natural Gas Piping Codes and Standards / 55
3.2 General Industrial Utilities Piping Fundamentals / 56
3.3 Manual Isolation Valves / 57
3.4 Blanks or Blinds / 58
3.5 Steel Pipe Joining Methods / 60
3.6 Fastener Issues: When a Bolt Is Not Simply a Bolt / 63
Notes and References / 64
4 Gas Supply System Issues 65
4.1 Incoming Natural Gas Systems / 66
4.2 Piping Corrosion Protection / 71
4.3 Considerations for Limiting Access to Service Entrances / 77
4.4 Gas Supplies From Digesters and Landfills / 77
4.5 Incoming Propane Service Considerations / 79
Notes and References / 80
5 Gas Piping Repairs and Cleaning 81
5.1 Key Steps to Safe Gas Piping Repairs / 82
5.2 Planning the Project / 83
5.3 Isolation / 84
5.4 Prerepair Venting and Purging of Flammable Gases / 85
5.5 Leak Checking and Pressure Testing / 89
5.6 Postrepair Purge / 91
5.7 Reintroduction of Natural Gas: Startup / 91
5.8 Gas Sampling and Detection / 92
5.9 Nitrogen-Handling Issues to Consider / 95
5.10 The World of Gas Line Cleaning / 101
5.11 NFPA 54: Changes Related to Purging Issues / 110
5.12 Highlights of and Commentary Regarding the New NFPA 56 Standard / 111
Notes and References / 116
6 Understanding Fuel Trains and Combustion Equipment 117
6.1 Fuel Train Components and Their Purpose / 117
6.2 Basic Operations of Fuel Trains / 126
6.3 Oil Firing Systems / 138
6.4 Oven and Furnace Types / 140
Notes and References / 145
7 Understanding Boilers and Their Special Risks 147
7.1 Boiler Incident Statistics / 152
7.2 Boiler Types / 153
7.3 Boiler-Water-Level Safety Devices / 160
7.4 Boiler Pressure Safety Controls / 165
7.5 Safety Relief Valves / 165
7.6 Steam System Piping Special Issues / 168
Notes and References / 171
8 Controlling Combustion Risks: People 173
8.1 Personnel Issues / 175
8.2 Training / 177
8.3 Culture Changes / 179
8.4 Human Layers of Protection Analysis / 183
8.5 Contractor Issues / 192
Notes and References / 195
9 Controlling Combustion Risks: Policies 197
9.1 Policy Commandments for Fuel and Combustion System Safety / 199
9.2 Commandment I / 199
9.3 Commandment II / 201
9.4 Commandment III / 204
9.5 Commandment IV / 208
9.6 Commandment V / 208
9.7 Commandment VI / 209
9.8 Commandment VII / 215
9.9 Commandment VIII / 217
9.10 Commandment IX / 219
9.11 Commandment X / 222
Notes and References / 224
10 Controlling Combustion Risks: Equipment 227
10.1 Controlling Equipment Risks / 229
10.2 Testing of Fuel Train Safety Interlocks / 234
10.3 Rebuilt Safety Controls / 245
10.4 Valve Seat Leakage Tightness Testing / 246
10.5 Refractory and Equipment Outer Skin Problems / 253
Notes and References / 253
11 Global Perspective on Fuel and Combustion System Risks 255
11.1 Global Perspectives on Fuel and Combustion System Risks / 256
11.2 Highlights of the European Combustion World / 257
11.3 Fuel System Risks in Other Countries / 259
11.4 Differences in Types of Systems and Equipment From U.S. to Foreign Operations / 263
11.5 Fuel Issues / 265
Notes and References / 266
12 Business Contingency Planning 269
12.1 Business Interruptions From Fuel and Combustion Systems / 271
12.2 Sparing Philosophies for Components / 276
12.3 Flood and Water Damage / 277
12.4 When There is an Incident / 283
12.5 Conclusion / 285
Notes and References / 286
Appendix: Analysis of Real-Life Stories 287
Index 295