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RadTech UV & EB 2008, May 4-7, 2008 in Chicago. www.RadTech2008.com.

Furnaces: Combustion Safety Audits

The Challenge

Furnaces: Combustion Safety Audits A major aluminum manufacturer producing aluminum sheet and plate used in the fabrication of airliners, automobile bodies and framing required a safety inspection and audit on their existing furnace combustion systems. Prior to the safety audits, the furnaces did not meet electrical and mechanical safety specifications. Among the challenges of the project: lack of advanced safety logic; asbestos insulation in some of the wiring; and undependable valves and piping.

Combustion Services Group
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The PCT Solution

Furnaces: Combustion Safety Audits Familiarity with the customer's combustion standards, as well as NFPA combustion standards, made PCT Engineered Systems, LLC the integrator of choice to provide the resources for field and design research. PCT created documentation detailing the areas of the furnace not in compliance with current safety standards. PCT also developed bills of materials, drawing packages and work packages to allow the customer to receive quotes from contractors for specified work to upgrade furnaces. Allen-Bradley PLC's were installed and programmed to provide the integration of safety logic to current standards.

The major improvements to the customer's equipment included increased safety of the furnaces and replacement of outdated equipment. Some furnaces were modified to the extent of replacing all burner equipment (valves, burner tubes, fans, etc.) to allow for a more efficient and maintainable furnace.

PCT supplied the customer with extensive documentation detailing the required safety upgrades for each furnace. PCT also supplied the customer with detailed drawing and work packages to allow for quick and efficient upgrades. The work packages included the identification of old equipment to be replaced, asbestos wiring to be removed; and obsolete gas and nitrogen piping and valving. PCT also helped the customer with various design improvements relating to the furnace structure and control system.