Nfpa 87 RP For Fluid Heaters Presentationpdf PDF

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Rick Martin
Martin Thermal Engineering, Inc.
June 9, 2011
2
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 Introduction
 Past
 Present
 Future
 Conclusion
4
 Dr. Martin is not an employee or a representative of
NFPA – he is an NFPA member and a committee
volunteer, and his views may or may not represent
those of NFPA.
 This presentation gives a number of examples and
suggestions for safeguarding fluid heaters, but is by
no means a comprehensive guide to safety.
 The presenter strongly recommends familiarity with
and adherence to applicable safety regulations and
standards.
5
6
 This presenter investigated a fatal explosion involving
a large fluid heater.
 Human error was the direct cause of the explosion.
 Although NFPA 87 did not exist at the time of the

incident…
…and other NFPA standards were not applicable
…the incident likely would have been prevented if the
heater had been equipped with certain safeguards
recommended in NFPA 87.
7
 Human factors experts often recommend a
hierarchical approach to reducing risk:
 Eliminate – where possible, use a substitute that is less hazardous.
Ceramic fiber insulation vs. asbestos.
 Guard – when the object’s desired function is inherently
hazardous (e.g., saws are sharp and will cut), install physical
safeguards or safety controls. Automatic vs. manual shutoff valves.
 Warn – when it is impossible to eliminate or fully safeguard
against hazards, use warnings to help prevent accidents and
injuries. Warning sign – “Hot Surface”.
8
NFPA 87 guidance:
 Safety Shutoff Valves:

 8.7.2.1 Each main and pilot fuel gas burner system
should be separately equipped with two safety shutoff
valves piped in series.
 Safety Device Bypassing: Images: Wikipedia
 8.2.8 Safety devices should not be bypassed electrically
or mechanically.
 7.5.21 An inspection should be completed at least
annually to verify safety interlocks are present and have
not been bypassed or rendered ineffective.
Reproduced (paraphrased) with permission from NFPA 87 (2011) Recommended Practice for Fluid Heaters; Copyright © 2010, National
Fire Protection Association. This reprinted material is not the complete and official position of the NFPA on the referenced subject,
which is represented only the standard in its entirety.
9
Minimize fire and explosion hazards
that can endanger the fluid heater, the
building, or personnel.
Image copyright © NFPA 2011
10
 TELL US ABOUT YOUR BUSINESS: Check the description
that best fits your company.
1. MANUFACTURER – HEATING EQUIPMENT
2. MANUFACTURER – ACCESSORIES & FLUIDS
3. USER – PROCESS FLUID HEATER
4. USER – THERMAL FLUID HEATER
5. SERVICE & MAINTENANCE
6. CONSULTING & OTHER
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 NFPA publishes more than 300 fire safety codes and
standards that are used worldwide.
 Codes and Standards are updated every 3 to 5 years.
 Over 250 Technical Committees, comprised of
approximately 7,000 volunteers, administer the
codes.
 Technical Committees are comprised of members
representing a variety of balanced interests.
 Because the process addresses concerns of different

interest groups – it is considered a “consensus”
process.
13
 Many public requests for interpretation: Are
fluid heaters covered by existing NFPA standards?
 NFPA 85 (Boilers & Combustion Systems)

specifically excluded process heaters since the
1970s.
 NFPA 86 (Ovens & Furnaces) now excludes fluid

heaters, but the standard was never adequate to
address fluid heater safety.
Images copyright © NFPA 2011
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 In 2006, a task force began writing NFPA 87.
 The 2011 edition of NFPA 87 is the FIRST published
edition.
 The current document is a “Recommended
Practice”.
 A new Technical Committee on Fluid Heaters was
established in 2010.
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 Current Leadership:
 Chair: Al Underys, A. Finkl & Sons, Co.
 Secretary: Richard J. Martin, Martin Thermal Engineering, Inc.
 NFPA Staff Liaison: Derek Duval
 Principal Members (2011):
 5 Manufacturers
 4 Users
 2 Insurance
 5 Special Experts
 plus …3 Alternates
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 <Jamie to pipe in results here…>
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 Heat a Process Fluid to alter its properties:
 Separation (distillation, precipitation)
 Solubility Control
 Viscosity Control
 Chemical Synthesis/Decomposition
 Heat a Thermal Fluid to convey heat elsewhere:
 Safety (remote heating is flameless)
 Stability (high thermal mass of fluid)
 Precise Temperature Control (high Q-low ΔT; runaway unlikely)
 Delicate Product (eliminate hot spots, coking, local overheating)
 Sanitary Environment (cooking, dry cleaning)
 Low Energy Cost (compare to electric heating; air moving)
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 Adhesives  Pipe Tracing
 Autoclaves  Plastic Molding
 Chemical Processing  Platens, Presses, Rolls
 Food Processing  Quench Oil Warming
 Fryers  Rubber Processing
 Inks, Dyes, Paints  Sewage Processing
 Kettles, Reactors  Tank Farms
 Molten Salt  Tar, Asphalt
 Ore Processing  Textile Drying
 Ovens, Dryers
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 Closed-loop with minimal fluid losses
 Low system pressure compared to steam boiler
 Relatively high thermal efficiency; no blowdown
21
 At Fluid Heater:
 Heating system hazards (fire, explosion, electrocution)
 Fluid release (fire, environmental contamination)
 Fluid damage (overheating, thermal degradation)
 Heater damage (containment overheating, rupture)
 At Point of Use:
 Excessive temperature (overheating of work)
 Release of fluid into processing environment (contamination of work,
fire hazard)
 Release of fluid into worker environment (scald injury, chemical
hazard, fire hazard)
 Special Hazards:
 Unlike boilers, the fluid is usually combustible.
 Unlike ovens/furnaces, the substance being heated is under pressure.
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 TELL US ABOUT YOUR APPLICATION: Which category
of Fluid Heater use constitutes the greatest proportion of
your business?
 Chemical Processing
 Food Processing
 Drying (textiles, paper, powders) or Dry-cleaning
 Melting (plastic, tar, salt, etc.)
 Pressing (adhesives, printing, wood products)
 Other
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 The NFPA 87 information presented contains only
excerpts and highlights of the actual document.
 Sufficient time is not available to discuss all the

recommendations in NFPA 87.
 Attendees should obtain a copy of NFPA 87 or view

the online version.
Do not rely on this presentation to provide the

entirety of the guidance given in NFPA 87.
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 Standard.
 A document that contains only mandatory provisions using the
word “shall”.
 A form generally suitable for adoption into law.
 Recommended Practice.
 A document that is similar to a code or standard but contains
only nonmandatory provisions using the word “should”.
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 Chapter 1 – Administration
 Chapter 2 – References
 Chapter 3 – Definitions
 Chapter 4 – General
 Chapter 5 – Location and Construction
 Chapter 6 – Heating Systems
 Chapter 7 – Operation, Inspection, Maintenance
 Chapter 8 – Safety Equipment
 Chapter 9 – Class F Fluid Heaters
 Chapter 10 – Class G Fluid Heaters
 Chapter 11 – Class H Fluid Heaters
 Chapter 12 – Fire Protection
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 Content is “general”.
 Content applies to all fluid heater styles.
 Applicable: Any Thermal or Process Fluid Heater with
 (1) Fluid flowing under pressure.
 (2) Fluid indirectly heated.
 (3) Energy from combustion or electrical.
 Not Applicable:
 (1) Boilers covered by NFPA 85
 (2) Ovens/Furnaces covered by NFPA 86
 (3) Fired heaters in refineries and facilities covered by API standards
 (4) Air heaters for comfort
 (5) LP gas vaporizers
 (6) Solid fuel combustion systems
 (7) Listed heating equipment under 150,000 BTU/h
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 1.4 Retroactivity: Provisions do not apply to
installations that existed prior to the effective date of
the recommended practice. Where specified,
provisions are retroactive.
 1.5 Equivalency: Ok to use systems, methods, or
devices of equivalent or superior quality, strength, fire
resistance, effectiveness, durability, and safety.
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 5.1.3.2 Combustible materials should be located at a distance
to prevent ignition; minimum separation = 30 inches.
 5.2.4 Fluid heaters should withstand strains imposed by
expansion and contraction.
 5.2.5 Provide for draining fluid for maintenance and
emergencies.
 5.2.6 Provide access for inspection and maintenance.
 5.2.8 External surfaces in excess of 160°F (71°C) should be
guarded.
 5.2.16 Pressure vessels should be stamped as ASME Section I
or Section VIII.
 5.2.20 Stresses in unsupported tube lengths should not
exceed one-half of the stress to produce 1 percent creep in
10,000 hours.
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5.3 Explosion Mitigation. Explosion hazards should
be mitigated through one of the following:
 Containment
 Explosion relief
 Location
 Explosion suppression
 Damage limiting construction
 For additional information regarding explosion
protection, see NFPA 68 and NFPA 69.
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 7.2 Commissioning:
 Do not release fluid heater before safety checkout is complete.
 Ensure that set points of all interlocks are documented.
 7.3 Training:
 Operating, maintenance, and supervisory personnel should receive
regularly scheduled retraining and testing.
 Program should cover start-up, operation, shutdown, maintenance,
and emergency procedures.
 Program should be kept current and should be available for reference.
 7.5 Inspection, Testing, Maintenance:
 If fluid tests indicate unacceptable degradation or contamination,
replace the fluid.
 The user establishes and enforces the frequency and extent of the
inspection, testing, and maintenance program.
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 8.5 Fuel Safety Controls
 Pre-Ignition Purge
 Trial for Ignition
 8.6 Combustion Air Safety Controls
 Airflow proved before ignition
 8.7 Safety Shutoff Valves
 Each burner system equipped with two SSOV in series.
 8.8 Fuel Pressure Switches
 Low Fuel Pressure Interlock (upstream of SSOV)
 High Fuel Pressure Interlock (downstream of pressure
regulator)
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 8.9 Combustion Supervision.
 Maximum flame failure response time of 4 seconds
 Safe-start check
 Interlocked into the combustion safety circuitry
 8.15 Stack Excess Temperature
 Actuation of interlock should cut off the heating system and if
process fluid is combustible, the process fluid supply.
 8.16 Fluid Excess Temperature
 Fluid excess temperature measurement on heater outlet.
 Set point should be no higher than the maximum temperature
specified by the fluid manufacturer.
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 8.3 Logic Systems
 Safety instruments should be listed.
 Activation of a safety interlock should result in a safety shutdown.
 Safety Logic should be carried out with one of the following:
 Listed safety controller (BMS) and hardwired instruments.
 PLC listed for “combustion safety service”.
 General-purpose PLC used in accordance with recommendations in 8.4.
 8.4 Programmable Logic Controllers
 Memory that retains information on loss of system power.
 Minimum mean-time-between-failure rating of 250,000 hours.
 Only one safety device should be connected to a PLC input or output.
 Output checking for PLC outputs controlling fuel safety shutoff valves.
35
 8.4 Programmable Logic Controllers. The PLC should detect
the following conditions:
 Failure to execute any program or task containing safety logic
 Failure to communicate with any safety input or output
 Changes in software set points of safety functions
 Failure of outputs related to safety functions
 Failure of timing related to safety functions
 8.4.2.8 The following devices and logic should be hardwired
external to the PLC:
 Manual emergency switch
 Combustion safeguards
 Safe-start checks
 Ignition transformers
 Trial-for-ignition periods
 Excess-temperature controllers
 Valve-proving systems
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 1.1.4 Class F heaters have fluid inside the tubes with a
relatively constant flow rate.
 9.1 General
 Design Class F heaters for relatively uniform fluid flow through parallel
tube passes.
 Determine maximum allowable bulk temperature based on maximum
allowable film temperature that prevents rapid fluid degradation.
 Determine minimum flow rate based on maximum bulk temperature
and maximum heat input rate.
 Provide expansion tank for closed loop circuits.
37
 9.2.1 Pumps.
 Pumps with mechanical seals should be air- or water-cooled, or
magnetically-coupled pumps should be used.
 Positive displacement pumps should incorporate features to
ensure minimum flow is maintained.
 9.2.2 Catch Tank.
 Direct effluent from pressure relief devices, vents and drains to
a closed catch tank.
 Prevent siphoning of catch tank contents back into system.
 Provide liquid level indicator.
38
 9.2.3 Strainers
 One strainer in suction piping of each pump.
 Place pressure gauge between strainer and pump inlet to
indicate blockage.
 9.2.5 Expansion Tanks.
 Expansion tank should be connected upstream of pump.
 A low level switch should be provided.
 Local or remote indication of tank level should be provided.
39
 9.3 Safety Devices for Class F Heaters
 Low fluid flow
 High stack temperature
 High process fluid outlet temperature
 Process low flow limit
 Low expansion tank fluid level
40
 Chapter 10. Class G heaters have fluid inside the
tubes with a modulated flow rate and firing rate
 RESERVED
 Chapter 11. Class H heaters have a heat source
(combustion or electricity) inside the tubes
 RESERVED
41
 Chapter 12 Content:
 User is responsible for determining need for fire protection
(manual/automatic, fixed/portable)
 Consult NFPA 10, 11, 12, 13, 15, 17, 750 for guidance on sprinklers
and other extinguishing systems.
 Obtain approval from Authority Having Jurisdiction (insurance
company or local fire department)
 Halting an internal fire (Section 12.1.5):
 Shut down heating system
 Stop combustion air blower
 Open outlet dampers to prevent BLEVE, implosion
 Depressurize and drain fluid to an approved location
42
 Used welded and flanged connections (not threaded) to
minimize leakage.
 Follow gasket manufacturer’s recommendations for
torquing flange bolts.
 Prevent leaking fluids from accumulating in thermal
insulation:
 Mount valve stems sideways to direct flow away from pipes.
 Use closed cell insulation.
 Eliminate contaminants inside piping:
 Dirt, mill-scale, weld-splatter can increase friction and reduce bulk fluid
velocity causing overheating.
 Fluid overheating can lead to internal coking, which adds a layer of
thermal resistance and may lead to tube rupture.
 Perform daily/weekly system checks (liquid, vapor leaks)
43
 Jamie to pipe in results here…
44
45
46
 11/23/2012 Proposal Closing Date
 06/21/2013 Report on Proposals
 08/30/2013 Comment Closing Date
 02/21/2014 Report on Comments
 04/14/2014 NITMAM Closing Date
 06/02/2014 General Meeting (Floor Vote)
 08/17/2014 (approx) 2015 Edition Published
47
 Submitter Info.
 Proposed change in legislative

format (i.e., strikeout, underline).
 Substantiation.
 Obtain proposal form:

 http://www.nfpa.org/assets/files/pdf/DocProp.pdf
48
 Content of Application:
 Qualifications of Applicant
 Organization Representing
 Source of Funding
 Committee growth is limited.
New members are added only

once or twice per year.
 http://www.nfpa.org/assets/files/pdf/TCApp.pdf
49
 The document page for NFPA 87 can be
found at:
 www.nfpa.org/87
Document can be viewed online by

NFPA members before buying.
 Document can be procured in hardcopy

or PDF format.
50
 Will NFPA 87 become a “Standard” in the 2015
cycle?
 New content for Class G, H fluid heaters?
 Add content for solid-fuel fired heating systems.
 Others? (…audience may submit questions)
51
52
The 2011 Edition of NFPA 87 is now available for
manufacturers, users, and insurers of fluid heaters.
 To affect the content of the 2015 edition, public

proposals may be submitted to NFPA.
 Deadline for proposals is November 23, 2012.
 This presentation may be downloaded per instructions

given at the end of the webinar.
 Questions? …please contact:
Rick Martin, Martin Thermal Eng. Linda Becker, Process Heating Magazine
rmartin@martinthermal.com beckerl@bnpmedia.com
+1 (310) 937-1424 +1 (847) 405-4020
53
 With process heating equipment,
consequences of failure can be catastrophic…
 Protect your most valuable assets:
 Your personnel
 Your plant
 Your reputation
 Think Safety !
54

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 Human error was the direct cause of the explosion.

 Although NFPA 87 did not exist at the time of the

 Safety Shutoff Valves:

Image copyright © NFPA 2011

 Because the process addresses concerns of different

 NFPA 85 (Boilers & Combustion Systems)

 NFPA 86 (Ovens & Furnaces) now excludes fluid

 Low system pressure compared to steam boiler

 Relatively high thermal efficiency; no blowdown

 Sufficient time is not available to discuss all the

 Attendees should obtain a copy of NFPA 87 or view

Do not rely on this presentation to provide the

 Proposed change in legislative

 Obtain proposal form:

Image copyright © NFPA 2011

 Committee growth is limited.

New members are added only

Image copyright © NFPA 2011

Document can be viewed online by

 Document can be procured in hardcopy

 New content for Class G, H fluid heaters?

 Add content for solid-fuel fired heating systems.

 Others? (…audience may submit questions)

 To affect the content of the 2015 edition, public

 This presentation may be downloaded per instructions

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