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Interlock tests procedure for industrial boilers

Tuesday, March 21, 2017   By: Mr. Invisible [2130] 0 Stars
Dear users,

do you have good references about best practices and recommendations about interlock tests procedures for industrial boilers? Of course NFPA 85 is a must read, but Im trying to go deeper in this subject and NFPA is not very descriptive about interlock tests, intervals, etc.

My idea is to understand what we users are doing and maybe share ideas/good practices to improve safety.

Info about boilers I work with for reference:
IHI Boiler
MCR: 400 t/h
Pressure: 120 bar
Temp: 538 oC
Has DCS for control and PLC for BMS functions

Best regards.

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Thursday, March 23, 2017   By: Ross [390] 5 Stars
Indeed your water tube boiler is a large industrial boiler at 800,000 pounds per hour at 1800 psi and at that size online testing of fuel train, drafting, combustion, steam pressures, and drum level controls and permissives and interlocks would not be regularly tested on line. Operators and supervisors must ensure the controls and in some cases interlocks are functioning by directly observing the operation and start up to shut down, but they must be trained and skilled enough to know how they function and know their set points.

In NFPA 85 titled boilers and combustion system hazards code relies on the operators to ensure their functioning which NFPA 85 spells out in the code repeatedly.

Unfortunately that’s not what you’re looking for, since you may be seeking detailed procedures that can be found when testing permissives and interlocks on boilers 1/10 the size of yours, which is more commonly tested. Although, it is not uncommon in a large industrial boiler to have the permissives and interlocks tested before startup, but in those cases I would expect operators to be trained and skilled with the support of supervisors and management where the supervisors are directly instituting the testing through the operators with direct assistance with qualified instrumentation personnel.

Drum level controls would be done in on the way up and on the way down with the same involvement of staff.

Instrumentation technician or technicians should have a large role to play in testing permissives of interlocks to the final elements whether it’s a safety shutoff valve or a motor control relay.

Seems to me you’re asking the right questions.


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Saturday, April 01, 2017   By: Greg Burns [1953] 0 Stars
As a suggestion you may want to consult your insurance carrier for suggestions. If it is one of the companies such as FM Global they should be able to assist you on what testing is required as well as best practice.

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