NFPA 87 RP For Fluid Heaters (Presentation) PDF

Interested in conducting your own webinar? Email webinars@bnpmedia.
com
Rick Martin
Martin Thermal Engineering, Inc.
June 9, 2011
2
Archive
www.process-heating.com
Add to your favorites
Introduction
Past
Present
Future
Conclusion
4
Dr. Martin is not an employee or a representative of
NFPA he is an NFPA member and a committee
volunteer, and his views may or may not represent
those of NFPA.
This presentation gives a number of examples and
suggestions for safeguarding fluid heaters, but is by
no means a comprehensive guide to safety.
The presenter strongly recommends familiarity with
and adherence to applicable safety regulations and
standards.
5
6
This presenter investigated a fatal explosion involving
a large fluid heater.
Human error was the direct cause of the explosion.
Although NFPA 87 did not exist at the time of the

incident
and other NFPA standards were not applicable
the incident likely would have been prevented if the
heater had been equipped with certain safeguards
recommended in NFPA 87.
7
Human factors experts often recommend a
hierarchical approach to reducing risk:
Eliminate where possible, use a substitute that is less hazardous.
Ceramic fiber insulation vs. asbestos.
Guard when the objects desired function is inherently
hazardous (e.g., saws are sharp and will cut), install physical
safeguards or safety controls. Automatic vs. manual shutoff valves.
Warn when it is impossible to eliminate or fully safeguard
against hazards, use warnings to help prevent accidents and
injuries. Warning sign Hot Surface.
8
NFPA 87 guidance:
Safety Shutoff Valves:

8.7.2.1 Each main and pilot fuel gas burner system
should be separately equipped with two safety shutoff
valves piped in series.
Safety Device Bypassing: Images: Wikipedia
8.2.8 Safety devices should not be bypassed electrically
or mechanically.
7.5.21 An inspection should be completed at least
annually to verify safety interlocks are present and have
not been bypassed or rendered ineffective.
Reproduced (paraphrased) with permission from NFPA 87 (2011) Recommended Practice for Fluid Heaters; Copyright 2010, National
Fire Protection Association. This reprinted material is not the complete and official position of the NFPA on the referenced subject,
which is represented only the standard in its entirety.
9
Minimize fire and explosion hazards
that can endanger the fluid heater, the
building, or personnel.
Image copyright NFPA 2011
10
TELL US ABOUT YOUR BUSINESS: Check the description
that best fits your company.
1. MANUFACTURER HEATING EQUIPMENT
2. MANUFACTURER ACCESSORIES & FLUIDS
3. USER PROCESS FLUID HEATER
4. USER THERMAL FLUID HEATER
5. SERVICE & MAINTENANCE
6. CONSULTING & OTHER
11
12
NFPA publishes more than 300 fire safety codes and
standards that are used worldwide.
Codes and Standards are updated every 3 to 5 years.
Over 250 Technical Committees, comprised of
approximately 7,000 volunteers, administer the
codes.
Technical Committees are comprised of members
representing a variety of balanced interests.
Because the process addresses concerns of different

interest groups it is considered a consensus
process.
13
Many public requests for interpretation: Are
fluid heaters covered by existing NFPA standards?
NFPA 85 (Boilers & Combustion Systems)

specifically excluded process heaters since the
1970s.
NFPA 86 (Ovens & Furnaces) now excludes fluid

heaters, but the standard was never adequate to
address fluid heater safety.
Images copyright NFPA 2011
14
In 2006, a task force began writing NFPA 87.
The 2011 edition of NFPA 87 is the FIRST published
edition.
The current document is a Recommended
Practice.
A new Technical Committee on Fluid Heaters was
established in 2010.
15
Current Leadership:
Chair: Al Underys, A. Finkl & Sons, Co.
Secretary: Richard J. Martin, Martin Thermal Engineering, Inc.
NFPA Staff Liaison: Derek Duval
Principal Members (2011):
5 Manufacturers
4 Users
2 Insurance
5 Special Experts
plus 3 Alternates
16
<Jamie to pipe in results here>
17
18
Heat a Process Fluid to alter its properties:
Separation (distillation, precipitation)
Solubility Control
Viscosity Control
Chemical Synthesis/Decomposition
Heat a Thermal Fluid to convey heat elsewhere:
Safety (remote heating is flameless)
Stability (high thermal mass of fluid)
Precise Temperature Control (high Q-low T; runaway unlikely)
Delicate Product (eliminate hot spots, coking, local overheating)
Sanitary Environment (cooking, dry cleaning)
Low Energy Cost (compare to electric heating; air moving)
19
Adhesives Pipe Tracing
Autoclaves Plastic Molding
Chemical Processing Platens, Presses, Rolls
Food Processing Quench Oil Warming
Fryers Rubber Processing
Inks, Dyes, Paints Sewage Processing
Kettles, Reactors Tank Farms
Molten Salt Tar, Asphalt
Ore Processing Textile Drying
Ovens, Dryers
20
Closed-loop with minimal fluid losses
Low system pressure compared to steam boiler
Relatively high thermal efficiency; no blowdown
21
At Fluid Heater:
Heating system hazards (fire, explosion, electrocution)
Fluid release (fire, environmental contamination)
Fluid damage (overheating, thermal degradation)
Heater damage (containment overheating, rupture)
At Point of Use:
Excessive temperature (overheating of work)
Release of fluid into processing environment (contamination of work,
fire hazard)
Release of fluid into worker environment (scald injury, chemical
hazard, fire hazard)
Special Hazards:
Unlike boilers, the fluid is usually combustible.
Unlike ovens/furnaces, the substance being heated is under pressure.
22
TELL US ABOUT YOUR APPLICATION: Which category
of Fluid Heater use constitutes the greatest proportion of
your business?
Chemical Processing
Food Processing
Drying (textiles, paper, powders) or Dry-cleaning
Melting (plastic, tar, salt, etc.)
Pressing (adhesives, printing, wood products)
Other
23
The NFPA 87 information presented contains only
excerpts and highlights of the actual document.
Sufficient time is not available to discuss all the

recommendations in NFPA 87.
Attendees should obtain a copy of NFPA 87 or view

the online version.
Do not rely on this presentation to provide the

entirety of the guidance given in NFPA 87.
24
Standard.
A document that contains only mandatory provisions using the
word shall.
A form generally suitable for adoption into law.
Recommended Practice.
A document that is similar to a code or standard but contains
only nonmandatory provisions using the word should.
25
Chapter 1 Administration
Chapter 2 References
Chapter 3 Definitions
Chapter 4 General
Chapter 5 Location and Construction
Chapter 6 Heating Systems
Chapter 7 Operation, Inspection, Maintenance
Chapter 8 Safety Equipment
Chapter 9 Class F Fluid Heaters
Chapter 10 Class G Fluid Heaters
Chapter 11 Class H Fluid Heaters
Chapter 12 Fire Protection
26
Content is general.
Content applies to all fluid heater styles.
Applicable: Any Thermal or Process Fluid Heater with
(1) Fluid flowing under pressure.
(2) Fluid indirectly heated.
(3) Energy from combustion or electrical.
Not Applicable:
(1) Boilers covered by NFPA 85
(2) Ovens/Furnaces covered by NFPA 86
(3) Fired heaters in refineries and facilities covered by API standards
(4) Air heaters for comfort
(5) LP gas vaporizers
(6) Solid fuel combustion systems
(7) Listed heating equipment under 150,000 BTU/h
27
1.4 Retroactivity: Provisions do not apply to
installations that existed prior to the effective date of
the recommended practice. Where specified,
provisions are retroactive.
1.5 Equivalency: Ok to use systems, methods, or
devices of equivalent or superior quality, strength, fire
resistance, effectiveness, durability, and safety.
28
5.1.3.2 Combustible materials should be located at a distance
to prevent ignition; minimum separation = 30 inches.
5.2.4 Fluid heaters should withstand strains imposed by
expansion and contraction.
5.2.5 Provide for draining fluid for maintenance and
emergencies.
5.2.6 Provide access for inspection and maintenance.
5.2.8 External surfaces in excess of 160F (71C) should be
guarded.
5.2.16 Pressure vessels should be stamped as ASME Section I
or Section VIII.
5.2.20 Stresses in unsupported tube lengths should not
exceed one-half of the stress to produce 1 percent creep in
10,000 hours.
29
5.3 Explosion Mitigation. Explosion hazards should
be mitigated through one of the following:
Containment
Explosion relief
Location
Explosion suppression
Damage limiting construction
For additional information regarding explosion
protection, see NFPA 68 and NFPA 69.
30
7.2 Commissioning:
Do not release fluid heater before safety checkout is complete.
Ensure that set points of all interlocks are documented.
7.3 Training:
Operating, maintenance, and supervisory personnel should receive
regularly scheduled retraining and testing.
Program should cover start-up, operation, shutdown, maintenance,
and emergency procedures.
Program should be kept current and should be available for reference.
7.5 Inspection, Testing, Maintenance:
If fluid tests indicate unacceptable degradation or contamination,
replace the fluid.
The user establishes and enforces the frequency and extent of the
inspection, testing, and maintenance program.
31
8.5 Fuel Safety Controls
Pre-Ignition Purge
Trial for Ignition
8.6 Combustion Air Safety Controls
Airflow proved before ignition
8.7 Safety Shutoff Valves
Each burner system equipped with two SSOV in series.
8.8 Fuel Pressure Switches
Low Fuel Pressure Interlock (upstream of SSOV)
High Fuel Pressure Interlock (downstream of pressure
regulator)
32
8.9 Combustion Supervision.
Maximum flame failure response time of 4 seconds
Safe-start check
Interlocked into the combustion safety circuitry
8.15 Stack Excess Temperature
Actuation of interlock should cut off the heating system and if
process fluid is combustible, the process fluid supply.
8.16 Fluid Excess Temperature
Fluid excess temperature measurement on heater outlet.
Set point should be no higher than the maximum temperature
specified by the fluid manufacturer.
33
34
8.3 Logic Systems
Safety instruments should be listed.
Activation of a safety interlock should result in a safety shutdown.
Safety Logic should be carried out with one of the following:
Listed safety controller (BMS) and hardwired instruments.
PLC listed for combustion safety service.
General-purpose PLC used in accordance with recommendations in 8.4.
8.4 Programmable Logic Controllers
Memory that retains information on loss of system power.
Minimum mean-time-between-failure rating of 250,000 hours.
Only one safety device should be connected to a PLC input or output.
Output checking for PLC outputs controlling fuel safety shutoff valves.
35
8.4 Programmable Logic Controllers. The PLC should detect
the following conditions:
Failure to execute any program or task containing safety logic
Failure to communicate with any safety input or output
Changes in software set points of safety functions
Failure of outputs related to safety functions
Failure of timing related to safety functions
8.4.2.8 The following devices and logic should be hardwired
external to the PLC:
Manual emergency switch
Combustion safeguards
Safe-start checks
Ignition transformers
Trial-for-ignition periods
Excess-temperature controllers
Valve-proving systems
36
1.1.4 Class F heaters have fluid inside the tubes with a
relatively constant flow rate.
9.1 General
Design Class F heaters for relatively uniform fluid flow through parallel
tube passes.
Determine maximum allowable bulk temperature based on maximum
allowable film temperature that prevents rapid fluid degradation.
Determine minimum flow rate based on maximum bulk temperature
and maximum heat input rate.
Provide expansion tank for closed loop circuits.
37
9.2.1 Pumps.
Pumps with mechanical seals should be air- or water-cooled, or
magnetically-coupled pumps should be used.
Positive displacement pumps should incorporate features to
ensure minimum flow is maintained.
9.2.2 Catch Tank.
Direct effluent from pressure relief devices, vents and drains to
a closed catch tank.
Prevent siphoning of catch tank contents back into system.
Provide liquid level indicator.
38
9.2.3 Strainers
One strainer in suction piping of each pump.
Place pressure gauge between strainer and pump inlet to
indicate blockage.
9.2.5 Expansion Tanks.
Expansion tank should be connected upstream of pump.
A low level switch should be provided.
Local or remote indication of tank level should be provided.
39
9.3 Safety Devices for Class F Heaters
Low fluid flow
High stack temperature
High process fluid outlet temperature
Process low flow limit
Low expansion tank fluid level
40
Chapter 10. Class G heaters have fluid inside the
tubes with a modulated flow rate and firing rate
RESERVED
Chapter 11. Class H heaters have a heat source
(combustion or electricity) inside the tubes
RESERVED
41
Chapter 12 Content:
User is responsible for determining need for fire protection
(manual/automatic, fixed/portable)
Consult NFPA 10, 11, 12, 13, 15, 17, 750 for guidance on sprinklers
and other extinguishing systems.
Obtain approval from Authority Having Jurisdiction (insurance
company or local fire department)
Halting an internal fire (Section 12.1.5):
Shut down heating system
Stop combustion air blower
Open outlet dampers to prevent BLEVE, implosion
Depressurize and drain fluid to an approved location
42
Used welded and flanged connections (not threaded) to
minimize leakage.
Follow gasket manufacturers recommendations for
torquing flange bolts.
Prevent leaking fluids from accumulating in thermal
insulation:
Mount valve stems sideways to direct flow away from pipes.
Use closed cell insulation.
Eliminate contaminants inside piping:
Dirt, mill-scale, weld-splatter can increase friction and reduce bulk fluid
velocity causing overheating.
Fluid overheating can lead to internal coking, which adds a layer of
thermal resistance and may lead to tube rupture.
Perform daily/weekly system checks (liquid, vapor leaks)
43
Jamie to pipe in results here
44
45
46
11/23/2012 Proposal Closing Date
06/21/2013 Report on Proposals
08/30/2013 Comment Closing Date
02/21/2014 Report on Comments
04/14/2014 NITMAM Closing Date
06/02/2014 General Meeting (Floor Vote)
08/17/2014 (approx) 2015 Edition Published
47
Submitter Info.
Proposed change in legislative

format (i.e., strikeout, underline).
Substantiation.
Obtain proposal form:

http://www.nfpa.org/assets/files/pdf/DocProp.pdf
48
Content of Application:
Qualifications of Applicant
Organization Representing
Source of Funding
Committee growth is limited.
New members are added only

once or twice per year.
http://www.nfpa.org/assets/files/pdf/TCApp.pdf
49
The document page for NFPA 87 can be
found at:
www.nfpa.org/87
Document can be viewed online by

NFPA members before buying.
Document can be procured in hardcopy

or PDF format.
50
Will NFPA 87 become a Standard in the 2015
cycle?
New content for Class G, H fluid heaters?
Add content for solid-fuel fired heating systems.
Others? (audience may submit questions)
51
52
The 2011 Edition of NFPA 87 is now available for
manufacturers, users, and insurers of fluid heaters.
To affect the content of the 2015 edition, public

proposals may be submitted to NFPA.
Deadline for proposals is November 23, 2012.
This presentation may be downloaded per instructions

given at the end of the webinar.
Questions? please contact:
Rick Martin, Martin Thermal Eng. Linda Becker, Process Heating Magazine
rmartin@martinthermal.com beckerl@bnpmedia.com
+1 (310) 937-1424 +1 (847) 405-4020
53
With process heating equipment,
consequences of failure can be catastrophic
Protect your most valuable assets:
Your personnel
Your plant
Your reputation
Think Safety !
54

NFPA 87 RP For Fluid Heaters (Presentation) PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

NFPA 87 RP For Fluid Heaters (Presentation) PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Interested in conducting your own webinar? Email webinars@bnpmedia.

Human error was the direct cause of the explosion.

Although NFPA 87 did not exist at the time of the

Safety Shutoff Valves:

Image copyright NFPA 2011

Because the process addresses concerns of different

NFPA 85 (Boilers & Combustion Systems)

NFPA 86 (Ovens & Furnaces) now excludes fluid

Low system pressure compared to steam boiler

Relatively high thermal efficiency; no blowdown

Sufficient time is not available to discuss all the

Attendees should obtain a copy of NFPA 87 or view

Do not rely on this presentation to provide the

Proposed change in legislative

Obtain proposal form:

Image copyright NFPA 2011

Committee growth is limited.

New members are added only

Image copyright NFPA 2011

Document can be viewed online by

Document can be procured in hardcopy

New content for Class G, H fluid heaters?

Add content for solid-fuel fired heating systems.

Others? (audience may submit questions)

To affect the content of the 2015 edition, public

This presentation may be downloaded per instructions

Das könnte Ihnen auch gefallen