Manual for Owners and Operators of Special Status Plants Risk

Manual for Owners and Operators of Special Status Plants Risk
BRITISH COLUMBIA SAFETY AUTHORITY
Manual for Owners and Operators of Special Status Plants
Risk Assessed and General Supervision
Date: March 12, 2012
Controlled Document: MAN -4000-03
I
TABLE OF CONTENTS
SECTION “A” ............................................................................................................................... 3
Introduction .................................................................................................................. 3
General Supervision Staffing Requirements ................................................................ 3
Risk Assessed Status Staffing Requirements.............................................................. 3
Registration Procedure ................................................................................................ 3
General Supervision................................................................................................. 4
Risk Assessed Status .............................................................................................. 4
Process Flow Chart ..................................................................................................... 6
SECTION “B” ............................................................................................................................... 7
Minimum Schedule of Controls .................................................................................... 7
Testing And Maintenance Requirements ..................................................................... 7
Minimum Requirements of Automatic Control Devices for Boilers ............................... 8
Low Water Cut-off Control .................................................................................................................... 8
Minimum Requirements of Automatic Control Devices for Refrigeration Plants .......... 8
High Compressor Discharge Pressure Alarm ...................................................................................... 8
High Level Alarm Suction Trap: Non-Critically-Charged Systems ....................................................... 8
Ammonia Monitoring for Safety ............................................................................................................ 8
Plant Audit Guideline ................................................................................................. 12
Purpose: ............................................................................................................................................. 12
1. Installation ...................................................................................................................................... 12
2. Training Program ........................................................................................................................... 12
3. Remote monitoring ......................................................................................................................... 12
4. Traceability ..................................................................................................................................... 12
5. Maintenance Program .................................................................................................................... 12
6. Emergency preparedness .............................................................................................................. 12
7. Documentation ............................................................................................................................... 13
APPENDIX .................................................................................................................................. 13
References ................................................................................................................ 13
DEFINITIONS ............................................................................................................................. 14
MAN-4000-03 (2012-03-12)
Page 2 of 15
SECTION “A”
Introduction
This manual has been developed in order to assist plant owners and operators to prepare for
the safety review of their plant when applying for special plant status registration. The purpose
of special plant registration is to give owners options for alternative staffing through the use of
control technology, effective management and additional training of plant personnel. This
manual is not intended to replace or interpret the requirements of the Safety Standards Act,
Safety Standards General Regulation and the Power Engineers, Boiler, Pressure Vessel and
Refrigeration Safety Regulation, CSA B51or the ASME Codes. In all cases, the Act and
Regulations are to be consulted with regards to specific requirements.
General Supervision Staffing Requirements
A plant may be registered as a general supervision status plant operation if the plant is not
located in an institution or public assembly occupancy premises.
A general supervision status plant operation requires the presence of a power engineer with the
appropriate class of certificate of qualification as determined by a plant safety review and as
required by a provincial safety manager.
Before registration of a general supervision status plant, a provincial safety manager may direct
administrative and technical specifications for that plant to be met.
A plant operating as a general supervision status plant must, as a minimum, have a power
engineer with the appropriate class of certificate of qualification who must inspect the plant in
accordance with conditions established by a provincial safety manager.
Risk Assessed Status Staffing Requirements
A plant operating under the risk assessed status plant category must, as a minimum, have a
power engineer with the appropriate certificate of qualification who
(a) Is on the premises of the plant not less than 7 hours per day or such greater time as
may be required by a provincial safety manager, and
(b) Inspects the plant in accordance with conditions established by a provincial safety
manager
Before registration of a risk assessed status plant, a provincial safety manager may direct
administrative and technical specifications for that plant to be met.
Registration Procedure
The following procedure must apply in all cases where requests for registration as a General
Supervision or a Risk Assessed status plant are made:
1. The capacity of plants eligible for registration are as follows:
MAN-4000-03 (2012-03-12)
Page 3 of 15
General Supervision
Applies to:
i.
ii.
iii.
iv.
v.
vi.
vii.
a power plant that does not exceed 30 m2 of boiler capacity,
a steam heating plant that does not exceed 200 m2 of boiler capacity,
a fluid heating or low pressure thermal fluid plant that does not exceed 500 m2
of boiler capacity,
a low temperature low pressure fluid plant that does not exceed 2 000 m2 of
boiler capacity,
an unfired plant that does not exceed 1 000 m2 of boiler capacity, or
a refrigeration plant that does not exceed a total plant capacity of 1 000 kW
prime mover nameplate rating
meets all the administrative and technical specifications issued by a provincial
safety manager after a successful review for the continuity under this program.
Risk Assessed Status
Applies to:
i.
ii.
iii.
iv.
v.
is a fluid heating plant or low pressure thermal fluid plant not exceeding 500 m2
of boiler capacity,
is a low temperature low pressure fluid plant that does not exceed 2 000 m2 of
boiler capacity,
is an unfired plant not exceeding 1 000 m2 of boiler capacity,
is a refrigeration plant not exceeding a total plant capacity of 1 000 kW prime
mover nameplate rating, or
meets all the administrative and technical specifications issued by a provincial
safety manager after a successful review for the continuity under this program.
Table 1
MAN-4000-03 (2012-03-12)
Table of Conversions
Metric
Imperial
(approx)
103 kPa
15 psi
1100 kPa
160 psi
100C
212F
121C
250F
30 m2
320 ft2
200 m2
2150 ft2
500 m2
5300 ft2
1000 m2
10750 ft2
2000 m2
21500 ft2
1000 kW
1340 hp
Page 4 of 15
2. The owner of the plant must submit an application form with the appropriate fee to the BC Safety
Authority, requesting that a plant be certified as a ‘General Supervision or Risk Assessed status’
operation plant.
The plant owner must state in the request that the plant meets all the requirements outlined in the
Safety Standards Act, and Power Engineers, Boiler, Pressure Vessel, and Refrigeration,
regulation and those requirements outlined in Section “B” of this document, and that all fees and
expenses for the documentation, audit, and inspection of the plant and its equipment to establish
its eligibility for registration as a ‘General Supervision or Risk Assessed Status’ operation plant,
will be fully paid to the BC Safety Authority.
3. The plant will have a technical review carried out by the BC Safety Authority, to determine that it
meets the minimum safety code standards and other mandated regulatory, technical, and
administrative requirements.
The Boiler Safety Officer responsible for the technical review will record in detail any additional
safety controls or procedures required for plant registration, and give a copy of the review report
to the owner of the plant.
This first technical review will be carried out by two Boiler Safety Officers.
Where additional requirements are identified in the review report, on completion of the required
work, the plant will be re-reviewed by the regional Boiler Safety Officer to ensure that the
necessary safety controls or conditions required for plant registration, as listed on the initial
review report have been complied with.
The Boiler Safety Officer may witness the testing of the safety systems to verify satisfactory
operation.
4. The Boiler Safety Manager, upon the recommendation of the Boiler Safety Officer, will authorize
that the plant be registered as General Supervision or Risk Assessed Status plant operation. A
General Supervision or Risk Assessed status plant registration certificate will also be issued at
this time.
The plant under General Supervision or Risk Assessed status can operate under terms and
conditions as laid out in the review report(s). The plant must meet all those terms and conditions
at all times in order to remain under this program.
5. The General supervision or Risk Assessed status plant registration certificate is issued for two
years. The plant may be subject to a review prior to the renewal of the registration or at any time
if determined as necessary by a Boiler Safety Officer.
6. At the expiry of the plant registration certificate, certificate renewal is required upon payment of
renewal fee. This may be done with or without a review.
7. At any time the owner of the plant may withdraw their registration and go back to continuous
supervision or BC Safety Authority may cancel the registration for reason(s).
8. The review fees are comprised of:
 Application processing fee (one time)
 Initial review fee including travel costs for two inspector plus hourly rate for time spent at site
 Bi-annual renewal fee
 Review fees for travel cost plus hourly rate for time spent at site if a review is carried out
before registration renewal.
MAN-4000-03 (2012-03-12)
Page 5 of 15
Process Flow Chart
Submit application with
application fee
Administrative review
Meet requirement
Yes
No
Client request for initial
safety audit
Cancel the application and
inform client
Conduct initial safety audit
Plant is under continuous
supervision
End of
process
Audit successful
Need improvement
Plant is under the program
with conditions as given in
audit report
Plant meet the requirement
and request for review audit
Plant cannot be under this
program for reasons
Review audit by local BSO
Bi-annual paid
Review audit or Client
withdraw application
MAN-4000-03 (2012-03-12)
Page 6 of 15
SECTION “B”
Minimum Schedule of Controls
As boilers, pressure vessels, and refrigeration plants vary to a great extent in individual design
and operational features, it is not possible to list the exact type, make, or model, of automatic
controls and other electronic monitoring devices needed to safeguard all installations.
Based on historical data and practical operating experience of plants, and records indicating
principal causes of accidents, minimum mandatory control requirements have been established.
These minimum requirements will comprise the main additional safety features when plants are
run on automated and/or computerized safety control systems, without full time continuous
attendance by power engineers and/or operators. The control and alarm/notification system
used in a plant must be acceptable to the review team.
Where audio-visual alarms and/or other approved visual read-out systems are employed, they
must be located in the boiler room or refrigeration machinery room, as well as outside an
entrance to the room, selected by the owner, which is acceptable to the review team. The plant
must have visual and audio alarms that may be equipped with silencing buttons located in their
immediate vicinities.
Testing And Maintenance Requirements
Once a plant is installed and its minimum schedule of controls established for safe operation,
periodic testing of all controls and safety devices becomes necessary to determine that they are
operating as designed.
To ensure safe operation of the controls, the owner must:

Plan inspection and testing activities on a periodic basis.

Inspect and test as planned, recording all results.

Promptly initiate corrective action in the event of non-conformance or malfunction of any
equipment.

Maintain records, log books, and bound diaries as evidence that tests, inspections and
corrective actions are carried out in accordance with the plan, showing the date of
test/inspection, non-conformance, basis of acceptance, identity of the items tested and
inspected, the action taken and the name of the power engineer or licensed contractor
who made the tests, adjustments, or corrective actions.

Carry out a preventative maintenance program in accordance with the manufacturers’
guidelines and all pertinent safety codes. This maintenance shall be done by a power
engineer or licensed contractor of the required class.

Keep records of all maintenance work performed on the plant.

On approval of General Supervision or Risk Assessed Status operation provide the BC
Safety Authority with a letter stating the name and qualifications of the certified individual
MAN-4000-03 (2012-03-12)
Page 7 of 15
or the name and license number of the current British Columbia licensed contractor hired
to perform all repairs and major maintenance to the equipment in the plant, or the
Registration Number of the qualified person, responsible for the maintenance program if
the work is performed by in-house personnel.
The intent of the testing and maintenance requirements is for owners to develop and implement
a ‘Preventative Maintenance Program’ of their own. The exact structure of a maintenance
program must be developed based on the type and complexity of the controls and equipment in
the plant. Nevertheless, a guideline can be developed allowing owners to recognize the basic
minimum mandatory testing and maintenance schedule necessary and vital to prevent where
possible, the occurrence of failures, accidents, and explosions. Also, all alarms and controls
must be monitored and responded to.
Minimum Requirements of Automatic Control Devices for Boilers
All boilers must meet the requirements of ASME CSD-1 or NFPA 85 Boiler and Combustion
Systems Hazards Code, current editions and in addition have the following additional control
devices:
Low Water Cut-off Control
This low water cut-off device is in addition to, and independent of, the one(s) normally
required on a unit of certain size or type and must serve no other purpose but fuel cutoff. The device, in addition to its normal function of burner shut-down, must initiate an
audio-visual alarm. The low water cut-ff must have a manual reset.
All alarms must be connected to a paging system. The paging system must alert a power
engineer(s) with the required certificate of qualification who can respond to the alarm.
Minimum Requirements of Automatic Control Devices for Refrigeration Plants
A refrigeration plant is also be eligible for registration as a General Supervision or Risk
Assessed status operation as specified in Section “A”.
The following provides a listing of minimum control and alarm requirements for refrigeration
plants. There must be continuous monitoring of refrigerant levels in the machinery room and if
the refrigerant is used outside the machinery room, additional refrigerant detectors will be
required.
High Compressor Discharge Pressure Alarm
These alarms must alert locally within the machinery room and to a paging system.
High Level Alarm Suction Trap: Non-Critically-Charged Systems
These alarms must alert locally within the machinery room and to a paging system.
Ammonia Monitoring for Safety
The ventilation system must be equipped with an audio-visual alarm to indicate failure of
the system. In continuous operating systems, an air-proving device interlocked to shut
down the refrigeration equipment must be used to verify the operation of the ventilation
MAN-4000-03 (2012-03-12)
Page 8 of 15
system. Periodic tests of detector(s), alarm(s), and mechanical ventilating system must
be performed in accordance with manufacturers’ recommendations and/or requirements
of the regulatory authority having jurisdiction. All alarms must be connected to a paging
system. The paging system must alert a power engineer(s) with the required certificate
of qualification or a refrigeration operator(s).
STAFFING LEVELS
FOR BOILER
PLANTS
EXEMPT FROM
STAFFING
REQUIREMENT
POWER PLANT up to 10 m2
STEAM HEATING PLANT up to 30 m2
FLUID HEATING PLANT up to 150 m2
LOW PRESSURE TFP up to 150 m2
LT LP FLUID PLANT up to 300 m2
AN UNFIRED PLANT up to 150 m2
POWER PLANT b/w 10 to 30 m2
STEAM HEATING PLANT b/w 30 to 200 m2
FLUID HEATING PLANT b/w 150 to 500 m2
LOW PRESSURE TFP b/w 150 to 500 m2
LT LP FLUID PLANT b/w 300 to 2000 m2
AN UNFIRED PLANT b/w 150 to 1000 m2
GENERAL SUPERVISION STATUS
PLANT OPERATION
Minimum of a Power Engineer to attend site as
required by the Boiler Safety Manager when the
plant is occupied or unoccupied and the Boiler
is in operation
MAN-4000-03 (2012-03-12)
CONTINUOUS STAFF
REQUIREMENTS
POWER PLANT over 10 m2
STEAM HEATING PLANT over 30 m2
FLUID HEATING PLANT over 150 m2
LOW PRESSURE TFP over 150 m2
LT LP FLUID PLANT over 300 m2
AN UNFIRED PLANT over 150 m2
INSTITUTIONAL OR
PUBLIC ASSEMBLY LOCATION
FLUID HEATING PLANT b/w 150 to 500 m2
LOW PRESSURE TFP b/w 150 to 500 m2
LT LP FLUID PLANT b/w 300 to 2000 m2
AN UNFIRED PLANT b/w 150 to 1000 m2
RISK ASSESSED
STATUS PLANT OPERATION
Minimum of a Power Engineer, to be
employed 7 hours per day when the plant is in
operation and with Basic Safety Awareness
Certified persons on staff on the other shifts
when the plant is occupied
Page 9 of 15
NOTES:
1. Public Assembly Buildings and Facilities may qualify ONLY under the risk assessed
plant registration Program.
2. Plants wishing to operate under non-continuous staffing levels must meet the capacity
criteria and undergo an audit.
3. A plant audit does not guarantee reduced staffing levels.
4. Plants must maintain the same conditions as demonstrated in the audit in order to
maintain their plant registration status.
5. Any changes to plant capacity, operating hours, certified personnel, plant production and
other variables must be reported to the British Columbia Safety Authority.
6. When changes do occur, a new audit may be conducted in order to recertify the plant
registration.
7. All plants will be audited on a periodic frequency to be established by the Boiler Safety
Manager.
Figure 1
STAFFING LEVELS FOR RISK ASSESSED STATUS
REFRIGERATION PLANTS
Public Assembly Buildings, Ice Arenas, Curling Rinks, Hospitals, Schools and
Colleges
UNDER
200 kW (A1, A2, B1)
50 kW (A3, B2, B3)
No Operating Staff Required
MAN-4000-03 (2012-03-12)
200 kW (A1, A2, B1) to 1000 kW
50 kW (A3, B2, B3) to 1000 kW
Risk Assessed Plant Operation Minimum of a
Power Engineer or a Refrigerator Operator to be
employed 7 hours per day every day when the
plant is in operation and with additional staff with
basic safety awareness certificates on the other
shifts
Over 1000 kW
Continuous Staffing
Operation Required when
Plant is in Operation
Page 10 of 15
Figure 2
STAFFING LEVELS FOR GENERAL SUPERVISION
STATUS REFRIGERATION PLANTS
Cold Storage Facilities, Indirect Cooling Facilities (except Public Assembly), Packing
Plants, Rooftop Chilling Units
UNDER
200 kW (A1, A2, B1)
50 kW (A3, B2, B3)
No Operating Staff Required
200 kW (A1, A2, B1) to 1000 kW
50 kW (A3, B2, B3) to 1000 kW
General Supervision Status Plant Operation
Minimum of a Power Engineer or a Refrigerator
to attend site as required by the Boiler Safety
Manager
Over 1000 kW
Continuous Staffing
Operation Required when
Plant is in Operation
NOTE 2:
1. Refrigeration Plants applying for reduced staff levels must be audited by the BC Safety
Authority and registered for either a General Supervision Status Plant operation, or a
Risk Assessed Plant Status Operation.
2. Plants must maintain the same conditions as demonstrated in the audit in order to
maintain their plant registration status.
3. Any changes to plant capacity, operating hours, certified personnel, plant production and
other variables must be reported to the BC Safety Authority.
4. When changes do occur, a new audit may be conducted in order to recertify the plant
registration.
5. All plants will be audited on a periodic frequency to be established by the Boiler Safety
Manager.
6. Plants operating under the Risk Assessed Plant Operation, or General Supervision
Status, will be required to have additional monitoring equipment and safety protection
devices such as refrigeration leak sensors, room temperature and pressure sensors, and
other safety devices as may be required by the Boiler Safety Officer to achieve the
equivalent level of safety.
MAN-4000-03 (2012-03-12)
Page 11 of 15
Plant Audit Guideline
Purpose:
The purpose of this guideline is to provide minimum requirements for Special Plant
Registration. The plant may require additional requirements based on the location, age of
the plant, employees experience and technology. This is for guidance only and should not
be taken as a guarantee for the successful audit.
1. Installation


Plant meets the applicable code requirements for installation
All required safety devices are installed, working and tested
2. Training Program



Written training program
Training provided on periodic basis and recorded
Provisions for occupational health and safety requirements as per WorkSafeBC
regulations
3. Remote monitoring

Acceptable arrangements for remote monitoring when plant is not supervised by Power
Engineer or Refrigeration Operator
4. Traceability

All units, safety devices, valves and piping systems are marked with a unique
identification which is traceable to the plant drawing operation and layout drawings
5. Maintenance Program




Written maintenance/inspection program as per manufacturer’s recommendation and
those of National Board Inspection Code and other related codes/standards adopted
under Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulations
Maintenance contract (if applicable)
Maintenance activities are identified and deliverable
Licensed contractor to provide services whenever outsourcing maintenance work
6. Emergency preparedness


Emergency rescue plan
o Emergency evacuation procedure
o Periodic review and drill program
o Emergency shutdown procedure
o Emergency contacts
o Emergency response times must be acceptable
Response time for emergencies to attend the site when plant is not supervised
MAN-4000-03 (2012-03-12)
Page 12 of 15
7. Documentation




Copy of latest applicable codes
Copy of the BC Safety Act and regulations
Management of plant related reports, log book, contract, services and archiving
Original certificate of qualification for operator(s) are posted
APPENDIX
References
1.
D-B6 041206 1 Registration Requirements for Risk Assessed and General
Supervision Status Plants Directive.
2.
Safety Standards Act - Section 30
3.
Power Engineers, Boiler, Pressure Vessel and Refrigeration Safety Regulation Sections 54, 55(1)(d), 56(1)(e)
4.
Directive: Registration and permit requirements for Boilers in Heating Plant
MAN-4000-03 (2012-03-12)
Page 13 of 15
DEFINITIONS
"boiler" means a vessel, in which by the application of heat,
a.) gas, steam or vapour is capable of being generated and pressurized, or
b.) a liquid is capable of being pressurized or heated
and includes fittings and boiler external piping associated with the vessel;
"high pressure steam plant" means an assembly of one or more boilers and includes ancillary
equipment, the pressure piping system and a pressure plant, in which steam or vapour is
generated at a pressure greater than 103 kPa;
"power plant" means a high pressure steam plant or a high pressure thermal fluid plant or a
high temperature high pressure fluid plant;
"low pressure steam plant" means an assembly of one or more boilers and includes ancillary
equipment, the pressure piping system and a pressure plant, in which steam or vapour is
generated at a pressure not exceeding 103 kPa;
"steam heating plant" means a heating plant that generates steam or vapour;
"heating plant" means
a.) an assembly of one or more boilers in which steam or other vapour may be generated at
a pressure not exceeding 103 kPa, or
b.) means an assembly of one or more boilers, other than a low-temperature, low-pressure
boilers, in which water or an aqueous solution may be heated to a pressure not
exceeding 1 100 kPa or a temperature not exceeding 121°C;
(Directive ………….)
"fluid heating plant" means a heating plant that heats fluid without vapourizing the fluid;
"low pressure thermal fluid plant" means an assembly of one or more thermal fluid boilers
that do not contain an expansible fluid and are protected with temperature control and safety
devices that will not permit the boilers to continue to operate should the temperature rise to or
above the vapour point of the contained thermal fluid at atmospheric pressure;
"low temperature low pressure fluid plant" means an assembly of one or more boilers,
including ancillary equipment, that contain liquid and operate at a working pressure of 206 kPa
or less and a temperature of 100°C or less;
"unfired plant" means a plant where heat from gas, steam or vapour or other heating medium
is supplied to heat exchangers or used directly for the purpose of heating a facility or a process
without combustion of a solid, liquid or gaseous fuel taking place on the premises;
"refrigeration plant" means an assembly of refrigeration equipment and includes a pressure
plant connected to it;
MAN-4000-03 (2012-03-12)
Page 14 of 15
Revision History
Revision
Revision Date
Revision history
Revised by
00
2004/12/10
New release
Alina Urloiu
01
2005/05/09
Revised the section on “Low Water Cut-off
Control” to align with Section 55 (1) (c) (i) of the
PEBPVR Safety Regulation
Alina Urloiu
02
2006/03/03
Revised language usage and grammatical
inconsistencies
03
2012/02/06
Revised to reflect changes in the regulations
and further requirement under this program
Stephanie Salido
Shabbir Ahmed
Approval
This document has been approved for adequacy by:
Ed Hurd
March 12, 2012
Safety Manager, Boilers and Pressure Vessels
MAN-4000-03 (2012-03-12)
Page 15 of 15
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement