Header
About this publication
PREFACE
FOREWORD
1 SCOPE AND GENERAL
1.1 SCOPE
1.2 APPLICATION
1.3 NEW DESIGNS AND INNOVATIONS
1.4 REFERENCED DOCUMENTS
1.5 DEFINITIONS
2 APPLIANCE DESIGN AND CONSTRUCTION
2.1 GENERAL DESIGN
2.1.1 Appliance design
2.1.2 Ladders or steps
2.1.3 Protection of equipment
2.1.4 Accumulation within cavity walls
2.1.5 Insulation
2.1.6 Ignition hazards
2.1.7 Strength of doors
2.1.8 Prevention of accidental fires
2.1.9 Free circulation
2.1.10 Adjusting devices
2.1.11 Air inlet guards
2.1.12 Systems for heating by hot fluids
2.1.13 Electrical equipment
2.1.14 Gas piping, fittings and components
2.2 MATERIALS
2.2.1 Suitability
2.2.2 Combustibility
2.3 SAFETY OF PERSONNEL
2.3.1 Working inside appliances
2.3.2 Door handles
2.3.3 Injury or burns
2.3.4 Projections
2.3.5 Explosion reliefs
2.4 OPERATING AND MAINTENANCE PROVISIONS
2.4.1 Control and safety equipment
2.4.2 Automatic appliance management systems
2.4.3 Manual functions
2.4.4 Flame to be visible to maintenance personnel
2.4.5 Visual indication of flame to operator
2.4.6 Removable components
2.4.7 Special tools
2.4.8 Cleaning
2.4.9 Maintenance provisions
2.5 EXPLOSION DAMAGE PROTECTION
2.5.1 Provision of protection
2.5.2 Explosion relief operation
2.5.3 Explosion relief location
2.6 TEMPERATURE HAZARDS
2.6.1 Components, floors, walls
2.6.2 Power failure
2.7 INSTRUCTIONS
2.7.1 Instructions
2.7.2 Additional information
2.8 MARKING
2.8.1 Appliance data
2.8.2 Special purpose appliance data
2.8.3 Indicators, gauges, and controls
2.8.4 Emergency stops
2.8.5 Colour code
3 COMBUSTION SYSTEM
3.1 GENERAL
3.1.1 General suitability
3.1.2 Requirements for a burner which can be retracted or swivelled
3.1.3 Fuel remaining in burner
3.2 IGNITION SYSTEM CONSTRUCTION
3.2.1 Location and fixing
3.2.2 Spark-ignition system
3.2.3 Manual ignition systems
3.2.3.1 Requirements for a manually-inserted gas torch
3.2.3.2 Point of ignition to be accessible
3.2.3.3 Explosion relief to be provided for a manually-ignited burner
3.3 SUPERVISION, CONTROL AND SAFE PROCEDURES
3.3.1 Introduction
3.3.2 General requirements
3.3.3 Automatic systems
3.3.4 Manual systems
3.3.5 Interlocking controls
3.4 STARTING AND IGNITION
3.4.1 Ignition procedures
3.4.2 Performance
3.4.3 Attempted re-ignition
3.4.4 Ignition during purging
3.4.5 Safe start check
3.4.6 Multiple main burner appliances
3.4.7 Sequential ignition of multiple main burners
3.4.8 Simultaneous ignition of multiple main burners
3.5 FLAME FAILURE DURING OPERATION
3.5.1 Flame supervision and failure protection
3.5.2 Flame failure response time
3.5.3 Relighting after flame failure
3.5.4 Extraneous ignition sources
3.6 MULTIFUEL FIRING
3.6.1 Application
3.6.2 Alternative firing
3.6.3 Simultaneous firing
3.7 SHUTDOWN PROCEDURES
3.7.1 Safety
3.7.2 Normal shutdown
3.7.3 Abnormal shutdown
3.8 PURGING
3.8.1 When to purge
3.8.2 Method of purging
3.8.3 Completeness of purging
3.8.4 Manually controlled purging
3.8.5 Proof of purge air
3.8.6 Dampers
4 CONTROL OF NON – FUEL COMBUSTIBLE ATMOSPHERES
4.1 SCOPE OF SECTION
4.2 PREVENTION AND RELIEF OF EXPLOSIONS
4.2.1 Explosion prevention
4.2.2 High concentration of volatiles
4.2.3 Explosion relief
4.2.4 Exceptions to provision of explosion relief on solvent ovens
4.2.5 Processes with solvents or combustible dust
4.2.5.1 Provision of dilution air
4.2.5.2 Recirculation air fans
4.2.5.3 Monitoring of solvent %LEL20 for variable dilution rates
4.2.6 Monitoring of input of releasable flammable substances
4.2.7 Appliances that operate without sources of ignition
4.3 AIR DILUTION AND PURGING
4.3.1 Method of providing dilution air
4.3.2 Dilution air quantities
4.3.2.1 Combustible atmospheres—dusts
4.3.2.2 Combustible atmospheres—solvents and combustible gases
4.3.3 Air distribution
4.3.4 Purging
4.4 VAPOUR AND DUST REMOVAL
4.4.1 Safe disposal
4.4.2 Incineration
4.4.2.1 General
4.4.2.2 Incineration of high %LEL20 concentration exhaust with inerting
4.4.2.3 Other incineration applications
4.4.3 Leakage of hazardous materials
5 INSTALLATION, COMMISSIONING, AND OPERATION
5.1 INSTALLATION REQUIREMENTS
5.1.1 Instructions
5.1.2 Defective equipment
5.1.3 Suitability for fuel, electricity
5.2 STANDARDS FOR WORKMANSHIP AND GOOD PRACTICE
5.2.1 Materials
5.2.2 Finish
5.2.3 Connection of services
5.3 LOCATION AND ACCESS
5.3.1 Building safety
5.3.2 Building structures
5.3.3 Safety and convenience
5.3.4 Combustible materials
5.3.5 Clearance for explosion relief
5.3.6 Explosion relief protection
5.3.7 Appliance security
5.3.8 Gas vent discharge
5.3.9 Foundations, supports
5.3.10 Lighting
5.3.11 Location of controls
5.4 FRESH AIR SUPPLY
5.4.1 Air supply
5.4.2 Air entries
5.4.3 Fan failure
5.5 FUEL SUPPLY SYSTEM
5.5.1 Fuel shut-off
5.5.2 Gas supply system
5.5.3 Liquid fuel supply system
5.5.4 Solid fuel systems
5.6 COMMISSIONING
5.6.1 Commissioning agent
5.6.2 Information
5.6.3 Data and reports
6 FLUES (CHIMNEYS), EXHAUST SYSTEMS AND DUCTS
6.1 GENERAL
6.1.1 Rationale
6.1.2 Removal of products of combustion
6.1.3 Provision of exhaust systems
6.1.4 Flues separate from exhausts
6.1.5 Common exhaust systems
6.1.6 Temperature hazards and comfort
6.1.7 Terminals for flues and exhaust ducts
6.2 FLUE DESIGN AND CONSTRUCTION
6.2.1 Construction
6.2.2 Performance
6.2.3 Common flues
6.2.4 Power flues
6.3 FLUE SUPPORTS
6.3.1 Direct-mounted flues
6.3.2 Free-standing flues
6.3.3 Guys, stays and supports
6.4 EARTHING
6.5 FLUE DAMPERS
6.5.1 Damper/fuel interlock
6.5.2 Damper settings
6.6 DUCTS
6.6.1 Construction
6.6.2 Joints
6.6.3 Cleaning
6.6.4 Condensation provisions
6.6.5 Dampers
7 ADDITIONAL REQUIREMENTS FOR LIQUID FUEL-FIRING SYSTEMS
7.1 GENERAL
7.2 LIQUID FUEL BURNER STARTING SYSTEMS
7.3 LIQUID FUEL PRE-TREATMENT
7.4 CONTROLS AND SAFETY DEVICES
7.4.1 General
7.4.2 Safety shut-off valve system requirements for liquid fuel supplies
7.4.2.1 Safety shut-off devices
7.4.2.2 Burners with a flow rate ≤30 kg/h
7.4.2.3 Burners with a flow rate >30 kg/h
7.4.2.4 Specific requirements for oils with viscosity exceeding 15 mm2/s (Centistokes) at 20°C
APPENDIX A
APPENDIX B
B1 GENERAL
B2 REGULAR TESTING
B3 PERSONNEL AND ORGANIZATION
B4 GENERAL OUTLINE OF PROCEDURES
B5 TESTING SCHEDULES
APPENDIX C
APPENDIX D
D1 METHODS, LIMITING CONDITIONS AND ALTERNATIVES
D2 SYMBOLS
D3 CALCULATING THE CRITICAL TIME, CASE A
D4 DERIVATION OF FORMULAS, CASE A
D5 CALCULATING THE CRITICAL TIME, CASE B
D6 DERIVATION OF FORMULA, CASE B
D7 DERIVATION OF FORMULA, CASE C
D8 EXAMPLES
D8.1 General
D8.2 Case A—using Equation D1
D8.3 Case A—using Equation D2
D8.4 Case B—Calculation method
D8.5 Case B—Using Figure D1
D8.6 Case C
APPENDIX E
E1 INTRODUCTION
E2 OUTLINE OF DESIGN PROCEDURE
E3 SYMBOLS
E4 DETERMINATION OF MAXIMUM ALLOWABLE PRESSURE
E4.1 Objective
E4.2 Determination of strength
E5 DETERMINATION OF RELIEF VENT AREA
E6 DETERMINATION OF THE OPENING CHARACTERISTICS OF THE RELIEF VENT CLOSURE
E6.1 Introduction
E6.2 Mass-gravity closure
E6.3 Hinged panels
E6.4 Closure that bursts to relieve pressure
E6.5 Spring-loaded panels
E7 LOCATION OF RELIEF VENTS ON APPLIANCES
E8 REFERENCES
APPENDIX F
F1 INTRODUCTION
F2 CALCULATION OF DILUTION AIRFLOW RATE
F3 DETERMINATION OF V
F4 DETERMINATION OF A
F5 DETERMINATION OF VA
F5.1 General
F5.2 Calculation when either V or A is unknown
F5.3 Calculation for mixed solvents
F6 DETERMINATION OF C
F6.1 General
F6.2 Determination of C for dust
F6.3 Simplified determination of C for solvent ovens
F7 DETERMINATION OF Q
F7.1 Continuous process oven
F7.2 Batch process ovens
F8 DETERMINATION OF F
F9 EXAMPLES OF CALCULATIONS
F9.1 Continuous oven
F9.2 Batch oven, below 120°C
F9.3 Batch oven, above 120°C
F10 MAXIMUM ALLOWABLE %LEL20 AT THE OPERATING TEMPERATURES
F10.1 General
F10.2 Combustible atmospheres—Solvents and combustible gases with sources of ignition
F10.3 Combustible atmospheres—solvents and combustible gases without sources of ignition
F11 EXAMPLES USING FIGURE 1 SOLVENT DRYING PROCESSES
F11.1 Continuous oven
F11.2 Continuous oven
F11.3 Fume incineration system connected to the print dryer
APPENDIX G
G1 FLUE GASES
APPENDIX H
H1 SCOPE
H2 STAGE 1: PRELIMINARY INSPECTION
H3 STAGE 2: ACTIVATION—RUN WITHOUT FUEL
H4 STAGE 3: ACTIVATION—RUN WITH FUEL
H5 STAGE 4: OPERATION
H6 STAGE 5: COMPLETION
APPENDIX I
I1 INTRODUCTION
I2 HAZOP OBJECTIVES
I3 SETTING UP A HAZOP
I4 INFORMATION REQUIRED
I5 HAZOP PROCEDURE
I6 HAZOP KEY WORDS
I6.1 Primary keywords (parameters)
I6.2 Secondary keywords (guidewords)
I7 HAZOP STUDY TEAM COMPOSITION
I8 RECORD KEEPING
I9 BENEFITS OF HAZOPs
APPENDIX J
APPENDIX K
APPENDIX L
APPENDIX M
APPENDIX N
