ARTICLES

Refresh your combustion knowledge and click on the articles below to learn how to make your plants more reliable, efficient and safe!

Testing & Inspections

Safe and Efficient Testing for Gas Train Safety

Safe and efficient gas train component testing is everyone’s goal; however, there are risks associated with various test methods and equipment that must be understood to make testing easier and more accurate. There are two possible approaches; this article discusses each.

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10 Tips on Combustion System Care

Whether a simple pilot burner or a large velocity burner, combustion equipment is designed to operate at a recognizable and repeatable level of performance. Learning about this equipment and appreciating how efficiently it can perform for you will save energy and maintenance budgets.

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Four Checkpoints to Add Value to Your Traditional Boiler Inspection

Each and every additional step taken to ensure people operating and/or using fuel-fired equipment are kept safe is well worth the time and effort. There is no measure of value that a single identified hazard can have on a facility and the people within it. This article provides four checkpoints to add value to your traditional boiler inspections.

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Boiler Maintenance to Prevent Combustion-Related Accidents

Human error and poor maintenance are the number one causes of combustion related accidents with boilers each year. The majority of these can be prevented with appropriate training. This article discusses three case studies surrounding common issues that have actually occurred to help stimulate the most important training you can provide: “Emergency Upset Drills.”

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Is Your Oven Telling You It's Unsafe

If you know what to listen and look for, your fuel train, purge system, ignition system and explosion-relief panels will tell you when your oven may be operating unsafely.

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Common Flame Scanner Failure Notice

Commonly, ultraviolet (non-self-checking) scanners fail on; indicating a flame is present. The article discusses sources of this common problem to help prevent this high risk hazard from occurring at your facility.

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Light-Off Problems Lead to Three Different Explosions!

Three separate industrial water tube boilers experienced fire-side explosions with boilers with a capacity of 20,000 to 40,000 pph and operated at 90 to 100 psig pressure. The explosions destroyed one boiler and damaged three others, fortunately no injuries were reported. The incidents came after the three boilers experienced trouble lighting-up, had fuel/air ratio, or burner capacity problems.

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Preventive Maintenance Technology Keeps Metal-forming Companies One Step Ahead

Preventive Maintenance (PM) programs can be made even better by adding new technologies such as airborne ultrasonic services for compressed air system leak detection and bearing monitoring, and infrared thermography to focus on electrical systems. Finding additional areas of wasted heat and energy innately result in cost savings, but the amounts may surprise you.

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Basic Gas Train Safety Controls and Concepts

Understanding basic gas train safety controls and concepts is critical to the daily operation of all facilities and the safety of every employee, yet awareness on this topic is lacking simply because it is complicated and misunderstood. It takes diligence and understanding to protect employees, facilities and industrial organizations from combustion-related incidents involving fuel-fired equipment.

 

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Boiler Safety Intuition

Diagnosing boiler problems sometimes takes almost all of the senses. Developing a safety intuition regarding boilers embeds certain things into all of your senses.

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Engineering Services

Fall Boiler Start-Up – Fuel System Tips to keep you Safe

For some, Fall is the time to get the boilers started up. This could be the start of another productive season out of your boilers, or their destruction, thousands of dollars in repair costs, or even explosion and death. Handling a seasonal start-up correctly can make all the difference in the world.

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The Impact of Combustion Controls

Combustion controls regulate a fuel-fired system’s air and fuel inputs to maintain the air/fuel ratio within the limits that are required for proper combustion. Any application can realize added benefits through updates or modifications to its combustion control system. With the various control systems available, though, how do you know which system will prove most beneficial for your operations?

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Preparations for Natural Gas Piping or Equipment Change-Out

Whether you work at an industrial plant, school, hospital, or even a large apartment building, your site’s facility staff should review their ability to shut off natural gas both outside at the main shut-off and inside at different locations. This article describes these and other items to review that could mean the difference between life and death in a time of emergency.

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Urgent Safety Notice For Air House Testing

Honeywell Combustion Safety’s Team has observed some unsafe practices while observing tradesmen doing Air Heater Safety Checks

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Strategies for Energy Reduction in Today's World

This paper focuses on operational and maintenance related low cost/no cost strategies to reduce fuel costs and improve safety, reliability, and quality; discussing the basics of many ovens and furnaces used throughout the steel industry and steel processing facilities.

 

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Don't Get Burned by a Retrofit Project

Requiring new burner or controls for your boiler, furnace or oven seems simple enough, but unless very careful planning is conducted and all involved are communicating vigilantly, trouble can arise quickly.

 

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Venting & Combustion Air: Two Biggest Installation Sins

The two biggest sins found time and time again within industrial facilities are related to combustion air and flue venting for fuel-fired equipment and their gas trains. Overlooking or committing these common mistakes can lead to increased risk of combustion related incidents, reduced equipment life, impaired production and an overall reduced level of safety for personnel working with and around the equipment.

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20 Tips to Cut Energy Costs

When it comes to cutting costs, many organizations focus on productivity, and although it is unmistakably very important, energy cost savings are also achievable yet often overlooked as solutions. Best operating practices, along with improved process heating technologies, can lead to significant energy savings at any plant.

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Industrial Heat Processing Equipment Reliability

Equipment reliability is at the core of production. Industrial facilities can’t operate and meet expected production standards and timelines when the combustion equipment utilized to create their product keeps tripping out, if the burners won’t stay lit, or if temperatures aren’t remaining consistent through the operating cycle. The issues seem to surround dirt and the ambient conditions that safety interlock components are asked to exist within. The two main culprits that have a negative impact on combustion system reliability are dirt and heat.

 

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Solenoid Vent Valve Failures

Valves are intended to regulate pressure and the amount of gas flowing through the unit; they are vitally important to the safe operation of fuel-fired equipment. However, without proper installation, regular inspections and maintenance, there are a wide variety of risks that can surface that those working with and around the equipment must be able to identify and mitigate.

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Pulse Firing Doubles Capacity and Cuts Fuel Costs

In multiple burner installations on industrial ovens and furnaces, pulse-firing technologies can improve temperature uniformity, reduce emissions and cut overall fuel costs… is it right for your process?

 

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Gas Hazards Management

Top 10 Underground Piping Questions

Ask yourself these 10 questions to identify how well you understand your underground piping systems, and evaluate your potential vulnerability to underground corrosion disasters.

 

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Protection From Underground Danger

The fuel distribution piping at your facility may be in danger from a natural occurring process. Corrosion is the cause of about 35% of all fuel pipeline accidents according to the US Department of Transportation’s Office of Pipeline Safety

 

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10 Tips to Help Avoid Natural Gas Piping Issues

Understanding gas piping can mean the difference between life and death in a time of emergency. Here are 10 tips to keep in mind to help you avoid natural gas piping issues.

 

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Preparations for Natural Gas Piping or Equipment Change-Out

Facility staff should should review and have the ability to shut off natural gas both outside at the main shut-off and inside at different locations. This article describes things to review that could mean the difference between life and death in a time of emergency.

 

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Why Little Leaks Ruin and Jeopardize Big Boilers

Just a little drip is a problem in both hot water and steam boiler systems. Pressure vessels don’t have to be big to hurt you.

 

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Natural Gas Pressure Testing - 10 Hazards to Avoid

Whenever gas piping is repaired, extended, or newly installed it must be purged. The rules and best practices for handling these situations are often misunderstood, even by those conducting the work. This has caused much pain and suffering including deaths, explosions, and the loss of billions of dollars in industrial assets. This document seeks to clear up some misconceptions and provide the insights needed to make sure this work is done safely at any facility by applying the codes and standards such as OSHA 1910, NFPA 54, and the equipment standards like NFPA 85 or NFPA 86.

 

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Anatomy of a Gas Piping Repair

Analyzing various gas piping repair issues, the piping repair process has been broken down into 10 main steps as are identified within this article.

 

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Training

Training: A Code Requirement AND Key to Safety

A common problem today in the manufacturing industry is extended downtimes or increased outsourced service calls due to the inability of personnel to troubleshoot combustion systems. Yet the remedy to this problem is simple: training. For industrial settings, training is imperative to safety, success and daily efficiency; it’s also required by U.S. and International Codes and Standards, find out if you’re meeting these requirements.

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Benefits of Combustion Workshops

CEC workshops educate professionals who work with fuel-fired equipment to help them create a safer work environment and keep individuals as well as their facilities in compliance with legally required codes and standards. Find out how our workshops can benefit you.

 

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Combustion Systems Codes 101

Each code has hundreds of pages covering the requirements for safe design, installation, operations, and maintenance of the respective equipment. The global economy, downsizing or right sizing has eliminated many engineering and maintenance personnel who could have stayed current with current codes. Find out what you need to know to stay safe and compliant.

 

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Making Sure Steam Piping is Safe

When screening high pressure (below 300 psig) piping systems normally encountered within industrial steam plants, safety issues related to the design and/or installation of pipe, valves, flanges, and components used in these systems must remain a top concern. Although not an all-inclusive guide to safe practices, this article provides insights for understanding and conducting a simple screening of a steam piping system.

 

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