Large Complex Safety Program Increases Safety, Fuel & Operations Efficiency

Image Ford 63 Building-01“We are proud that we can prove all state and legal rules and regulations are being followed.” – Maintenance Manager

“… a key component of our success was the disciplined approach maintained by the team and having the right people on board.” – Maintenance Manager

 

Challenge:

An automotive manufacturer began an extremely focused safety program for all gas-fired equipment used in space heating and hot water production at their complex of office and research facilities housing more than 10,000 employees within 2,000,000 sq. ft of property. Since most sites were not conducting testing of safety shut-off valves, safety relief valves, interlocks, or establishing consistent checklists or procedures, the risk of an event was high.

Image Ford 63 Building-03Solution:

Honeywell Combustion Safety engineers put together a multi-pronged, multi-media approach to training and inspections. This was accomplished by developing a series of 12 proprietary checklists detailing how to approach the gas-fired equipment. HCS utilized these checklists with the automotive personnel present to conduct the gas fired plant equipment testing and inspections. Training videos were disseminated to the group demonstrating how to apply the checklists and practices were reinforced with a series of in-person training sessions.

Image Ford 63 Building-02Benefit:

HCS evaluated more than 524 pieces of equipment with inputs 400,000 btu/hr and lower, 84 firing over 400,000 btu/hr, 50 boilers and 34 rooftop make up air houses. Notable findings included:

  • 11 of 25 air house MUA units had failed heat exchangers, a total of 44%!
  • Shut-off valves were not operable or leaking when in the closed position.
  • Abandoned units and gas lines lacked blanks or caps and the shut off valve was usually found open.
  • Low water cut outs on boilers were non-functional

This process provided the group with the ability to identify problems and schedule maintenance in advance, rather than their previous reactive approach, to create more efficient use of manpower overall.

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