Staying on the Right Side of NFPA 85: Controls Reviews for Compliance & Safety

Over time, modified control logic, changes in operating procedures, temporary fixes, and equipment additions can result in controls that no longer comply with governing standards. Compliance with NFPA 85 is important from a practical standpoint, as the code is written to ensure that power plants operate safely. More importantly, from a liability standpoint, compliance with NFPA 85 code minimizes the probability of an accident that can be expensive in multiple ways. TRAX can provide a controls review for compliance with NFPA 85 regulations with the following benefits:

• Safety of personal
• Reduce risk of equipment damage
• Increased reliability of equipment
• Prevent nuisance trips to increase plant productivity
• Increased efficiency of operation

Concerns of Safety and Liability

While it is not possible to prevent all power plant accidents, following the NFPA 85 guidelines greatly reduces the likelihood and severity of potential incidents. Incremental changes to plant controls through the years can make them both unsafe and noncompliant, increasing the potential for accidents such as a furnace implosion (which can cost millions of dollars to repair) or damage to draft fans, baghouses, or ductwork.

One example of an accident that could have been avoided with NFPA controls compliance is the 1999 Ford River Rouge explosion. On February 1, 1999, a natural gas explosion at the Dearborn, Michigan plant triggered secondary explosions of the coal dust that had accumulated on surfaces in the plant. As a result, six people died and another 14 were seriously injured. The power plant was completely rebuilt and $7 million in penalties were levied. Per the MIOSHA report, one of the major contributing factors to this incident stemmed from the Ford River Plant’s lack of NFPA-required flame sensing interlocks for the gas lines, which would have prevented natural gas flow into the furnace without any flame or igniter.1

Controls Review

In the case of an accident, it is vital to be able to establish that all reasonable efforts were made to follow NFPA 85 to maintain a safely operating plant. With a comprehensive controls review, TRAX can find and report any areas of noncompliance and make recommendations to return the plant to compliance. TRAX uses our many years of experience to describe how the code was interpreted for those sections that do not provide explicit numerical recommendations.

A controls study gathers all of the targeted controls data and sets up summary tables of the plant controls side-by-side with the relevant NFPA 85 requirements. The results are documented with tables showing where a plant is in compliance, along with recommendations to update all noncompliant logic. Areas of noncompliance can be as simple as a lack of necessary alarms, or as complicated as inadequate furnace implosion protection.

Conclusion

An independent control system review is one of the most economical ways to ensure a safer and more efficient plant. In addition, performing an independent review demonstrates due diligence to comply with established codes and regulations. To that end, TRAX conducts controls reviews to ensure that plants are compliant with NFPA 85, thus verifying that all recommendations are met without creating nuisance trips or other negative impacts to plant operation.

References

1. “Ford Settlement: State Reaches Historic Settlement Agreement with Ford and UAW”; MIOSHA news, Vol 3, No. 3, Fall 1999