Our Service Teams have uncovered over 13,000 critical safety issues in industrial facilities across the country; preventing tragedies and protecting the lives of every employee that works with and around the fuel-fired equipment.

Are you guilty of overlooking these common industrial facility dangers? Don’t turn your head to something that doesn’t look right just because “it’s always been that way;” it could be the difference between life and death!

Use the following sections to screen your combustion systems for lurking hazards, Be safe!

Click on each hidden hazard to find out what's wrong? 

A piece of cardboard is wedged in the switch

The piece of cardboard is wedged in the switch to keep it made (closed), allowing the safeties to be electrically bypassed. NFPA 86 8.2.8 (2015 Edition) states safety devices shall not be bypassed electrically or mechanically.

The handle on the lubricated plug valve has been installed in the wrong position

Look at the valve stem to properly determine the valve body position. For lubricated plug valves, also review the fitting at the end of the valve stem to determine if it has recently been injected with sealant. The handle for the valve does indicate the position of the valve body. When the handle is parallel to the gas line, the valve body is in the open position.

There is no corrosion protection

NFPA 54 states that piping passing through an exterior wall needs to be protected against corrosion by coating or wrapping. This Violates NFPA 54 Sec 7.2.1.

Benefits of Preventive Maintenance

What many don’t realize is if they had an effective PM program in place, there wouldn’t be emergencies or the elevated cost for those repairs and the downtime they cause. Preventive Maintenance (PM) Programs have a wide variety of benefits.

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The Air/Fuel Balancing Act

If a burner maintenance program doesn’t exist at your facility, it’s almost a guarantee that you’re wasting energy, reacting to unreliable production issues, and risking loss of property as well as your most value assets – people.

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Hazard Recognition: Industry’s Most Common

Over the last decade, our Inspections Team has uncovered over 13,000 critical safety issues that have gone unnoticed in industrial facilities across the country; preventing tragedies and protecting the lives of every employee that works with and around the fuel-fired equipment.

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Hazard Recognition: Human Error

Human error is the #1 cause of combustion related incidents! More than 90% of all workplace accidents are related to human error; involving unsafe behavior(s), unsafe condition(s), or a combination of both. You are your own worst enemy when it comes to combustion related incidents in the workplace!

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never let equipment operate with failed safety interlock components
high gas pressure switch is obviously wrong
A bypassed safety

You must look at the valve stem to properly determine the valve body position. For lubricated plug valves, also review the fitting at the end of the valve stem to determine if it has recently been injected with sealant. The handle for the valve does indicate the position of the valve body. When the handle is parallel to the gas line, the valve body is in the open position.

The key is still in the lock, rendering the lock useless

ONLY the authorized individual who placed the lock and tag onto the system is the one who is permitted to remove them. This procedure safeguards the system so it cannot be started up without the authorized individual’s knowledge.

The high gas pressure switch is wrong since its set point is pushed all the way to one end

Switches with set points like this, pushed to one end or the other, make for conditions that can’t be providing the proper level of protection. Verify that Safety Switch Set Points are not obviously wrong. This kind of situation should be an automatic indication that there is a problem. It also makes for switches that are probably out of range and possibly not correctly specified in the first place.

They jumpered the wire to bypass the safety

Never let equipment operate with failed safety interlock components. All of the safeties and interlock equipment in the world won’t help if someone has bypassed or jumpered-out safety controls. There is no possible substitute for proper training. Training has to include mock upset and hazard recognition drills.

There is a puddle of hydraulic fluid under the gas train valves

In this case, it's evident that hydraulic actuators have failed. The hydraulic fluid is only used to open the valve with a spring used to close the valve.  If fluid is low or missing, the valve may not open or only partially open which creates a hazardous condition.

The linkage is loose

Air flow can be compromised if linkages fall off or get loose. Likewise, air fuel ratios can be upset if linkages on jack-shafts come out of adjustment.

gas valve safety
The wire in question terminated with alligator clips

You should verify that suspicious wires don’t exist in the control panel that could indicate safety components being bypassed.

A very critical refractory issue!

A poorly installed hot-face refractory fell into the burner block and diverted the flame path behind the remaining refractory.

These emergency shut-off valves have no handles and the valves are not labeled

NFPA 54 states that the exterior emergency shut-off valves must be labeled