Note: Supplemental materials are not guaranteed with Rental or Used book purchases.
Purchase Benefits
What is included with this book?
JOHN R. PUSKAR is a licensed engineer and has over thirty years of experience working in the field of industrial fuels and combustion equipment safety. During that time, his company inspected and tested thousands of fuel trains at more than 500 plant sites in dozens of countries. His clients have included U.S. Steel, Ford Motor Co., General Motors, ConAgra, Tyson Foods, Pfizer, and Alcoa. Mr. Puskar has served on a number of key NFPA and ASME committees related to industrial fuels and combustion equipment safety. He has also been an expert retained for some of the worst industrial fuel and combustion systems disasters in history.
Preface 7
CHAPTER 1: What You Don’t Know Can KILL You! 11
1.1 Knowledge gaps in operating fuel systems and combustion equipment 14
1.2 Evaluating fuel systems and combustion equipment risks 16
1.3 The creation of fuel systems and combustion equipment codes and standards 17
1.4 Fuel systems codes and standards 22
1.5 Combustion equipment codes and standards 22
1.6 Other widely recognized codes and standards related organizations 24
1.7 Safety instrumented systems and safety integrity levels 26
1.8 The world of insurance and combustion equipment 27
1.9 Ever been to Jail? (Personal criminal liability) 30
CHAPTER 2: Combustion Basics 33
2.1 What is combustion? .35
2.2 Fuels 36
2.3 Heat/ignition 39
2.4 Oxygen/air 40
2.5 Combustion chemistry 42
2.6 Environmental emissions issues 44
2.7 Burner design issues 45
2.8 Draft systems 47
2.9 Understanding and evaluating flames 52
2.10 Air fuel ratio evaluations 57
CHAPTER 3: Natural Gas Piping Basics 62
3.1 Natural gas piping codes and standards 64
3.2 General industrial utilities piping fundamentals 65
3.3 Manual Isolation valves 67
3.4 Blanks/Blinds 68
3.5 Steel pipe joining methods 70
3.6 Fastener issues, (when a bolt is not just a bolt) 73
CHAPTER 4: Gas Supply System Issues 75
4.1 Incoming natural gas system issues 77
4.2 Piping corrosion protection 80
4.3 Issues related to limiting access to service entrances 86
4.4 Gas supplies from digesters and landfills 86
4.5 Incoming propane service issues 89
CHAPTER 5: Gas Piping Repairs & Cleaning 90
5.0 Six key steps to safe gas piping repairs 92
5.1 Planning the project 92
5.2 Isolation 94
5.3 Pre-repair venting and purging of flammable gases 94
5.4 Leak checking and pressure testing 99
5.5 Post repair purge 101
5.6 Re-introduction of natural gas/start-up 101
5.7 Gas sampling and detection 103
5.8 Nitrogen handling issues to consider 106
5.9 The world of gas line cleaning 111
5.10 NFPA 54, (The National Fuel Gas Code) changes related to purging issues 121
5.11 Highlights of and commentary regarding NFPA 56 121
CHAPTER 6: Understanding Fuel Trains and Combustion Equipment 127
6.1 Fuel train components, what they are and what they do 128
6.2 How fuel trains work 135
6.3 Oil firing systems 148
6.4 Oven and furnace types 151
Chapter 7: Understanding Boilers and Their Special Risks 157
7.1 Boiler Incident Statistics 163
7.2 Boiler types 164
7.3 Boiler water safety devices 170
7.4 Boiler pressure safety controls 173
7.5 Safety relief valves 174
7.6 Steam systems piping special issues 177
CHAPTER 8: Controlling Combustion Risks – People 180
8.1 People issues 182
8.2 Training 184
8.3 Culture changes 186
8.4 Human layers of protection analysis 190
8.5 Contractor issues 199
CHAPTER 9: Controlling Combustion Risks – Policies 203
9.0 The 10 policy commandments for fuel and combustion systems safety 205
9.1. Cmdt I: Have meaningful unique fuel and combustion system specifications 206
9.2 Cmdt II: Create lock out/tag out and line breaking/piping permit systems 208
9.3 Cmdt III: Perform Interlock and safety testing at least annually 211
9.4 Cmdt IV: Review systems for code changes and upgrade to stay current 215
9.5 Cmdt V: Maintain best practices and lessons learned processes 216
9.6 Cmdt VI: Develop start-up/shut down procedures 217
9.7 Cmdt VII: Implement regular training with validation processes 223
9.8 Cmdt VIII: Create a system to validate equipment vendors 225
9.9 Cmdt IX: Conduct regular fuel Fuel/Air ratio optimization programs 228
9.10 Cmdt X: Implement a management of change systems 230
CHAPTER 10: Controlling Combustion Risks – Equipment 233
10.1 Controlling Equipment Risks 235
10.3 Rebuilt safety controls 253
10.4 Valve seat leakage tightness testing 253
10.5 Refractory and equipment outer skin issues 261
CHAPTER 11: Global Perspective on Fuel & Combustion System Risks 263
11.1 Global perspectives on fuel and combustion systems risks 264
11.2 Highlights of the European Combustion World 265
11.3 Fuel system risks in other countries 267
11.4 Differences in types of systems and equipment from the U.S. to foreign operations 271
11.5 Fuel Issues 273
CHAPTER 12: Business Contingency Planning 275
12.1 Business Interruption from fuel systems and combustion equipment 277
12.2 Sparing philosophy 282
12.3 Flood and water damage 283
12.4 In case you have an incident 289
12.5 Conclusion 290
Appendices: Analysis of “Real Life Stories” with key words 292
The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.
The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.