Manual for Owners and Operators of Special Status Plants Risk
Contents
1. When changes do occur a new audit may be conducted in order to recertify the plant registration All plants will be audited on a periodic frequency to be established by the Boiler Safety Manager 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 Training Program Written training program Training provided on periodic basis and recorded Provisions for occupational health and safety requirements as per WorkSafeBC regulations Remote monitoring Acceptable arrangements for remote monitoring when plant is not supervised by Power Engineer or Refrigeration Operator Traceability All units safety2. 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 he capacity of plants eligible for registration are as follows MAN 4000 03 2012 03 12 Page 3 of 15 General Supervision Applies to l il lil IV V Vi Vil a power plant that does not exceed 30 m of boiler capacity a steam heating plant that does not exceed 200 m of boiler capacity a fluid heating or low pressure thermal fluid plant that does not exceed 500 m of boiler capacity a low temperature low pressure fluid plant that does not exceed 2 000 m of boiler capacity an unfired plant that does not exceed 1 000 m 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
3. devices valves and piping systems are marked with a unique identification which is traceable to the plant drawing operation and layout drawings Maintenance Program Written maintenance inspection program as per manufacturers 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 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 I 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 R
4. 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 history Revised by 2005 05 09 Revised the section on Low Water Cut off Alina Urloiu Control to align with Section 55 1 c i of the PEBPVR Safety Regulation 02 2006 03 03 Revised language usage and grammatical Stephanie Salido inconsistencies Revised to reflect changes in the regulations SUISSE and further requirement
5. is a fluid heating plant or low pressure thermal fluid plant not exceeding 500 m of boiler capacity is a low temperature low pressure fluid plant that does not exceed 2 000 m of boiler capacity is an unfired plant not exceeding 1 000 m 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 Tablei Table of Conversions Metric 3 Imperial bi approx 3403kPa tS psi 1000m 107501 200m 21500 MAN 4000 03 2012 03 12 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 Sa
6. under this program ieee mee 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
7. 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 TABLE OF CONTENTS OI N E TE 3 NFO OIC TI e p RR RI 3 General Supervision Staffing REQUIFEMENTS cccccseeceeseeeeeeeeeeeeeseesaeeeeeaeeesaeeeeeas 3 Risk Assessed Status Staffing REQUIFEMENTS ccccccseecesseeeecaeeceseeeeeseeeeeseeesaaeees 3 Registration Procedure cues cael soso ox Ead Eod G os coenGeel ue todas etae abate aal 3 General Supervisi N aan TE 4 Risk Assessed Status ccccccccccecececccccccecececcccacccccecaceceaeauscecececeauauetesceavauseenanenss 4 Process PIOW CII morreder ideea ederdi drdd eirean endrina eded eiai anake saia 6 SEC HONS zt REN RU RE 7 Minimum Schedule of Controls 0 c cccccccecececececcccecacecccececcauacecsceteaeauacaesceueaeauanaees 7 Testing And Maintenance ReEQuireMentts cccccscccseeceeeceeeseeeeeeceueceeeseeseeeseeeaeeeaees 7 Minimum Requirements of Automatic Control Devices for Boilers 8 Low Water Cut off GOUOL nex dod deste te ro beta ew peal he oe Yol dul dt dede dada Exo Yoon ben ads ut a rod 8 Minimum Requirements of Automatic Control Devices for Refrigeration Plants 8 High Compressor Discharge Pressure Alarm i
8. W No Operating Staff Required Risk Assessed Pant Opera non un ere Continuous Staffing Power Engineer or a Refrigerator Operator to be O TA mployed 7 hours per day every day when the pono UE jus Plant is in Operation plant is in operation and with additional staff with basic safety awareness certificates on the other shifts MAN 4000 03 2012 03 12 Page 10 of 15 Figure 2 200 kW A1 A2 B1 50 kW A3 B2 B3 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 to 1000 kW 50 kW A3 B2 B3 to 1000 kW Over 1000 kW No Operating Staff Required General Supervision Status Plant Operation Continuous Staffing Minimum of a Power Engineer or a Refrigerator Operation Required when to attend site as required by the Boiler Safety Plant is in Operation Manager 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 Plants must maintain the same conditions as demonstrated in the audit in order to maintain their plant registration status Any changes to plant capacity operating hours certified personnel plant production and other variables must be reported to the BC Safety Authority
9. 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 e Application processing fee one time e Initial review fee including travel costs for two inspector plus hourly rate for time spent at site e Bi annual renewal fee e 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 i Meet requirement Yes Client request for initial safety audit i Conduct initial safety audit NO Y Cancel the application and nem client Plant is under continuous f Audit successful Plant is under th
10. e 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
11. e program with conditions as given in audit report ww Bi annual paid MAN 4000 03 2012 03 12 supervision End of process Plant cannot be under this j UNA Necaiimprovemeni program for reasons Plant meet the requirement and request for review audit S S Review audit by local BSO Y Review audit or Client withdraw application 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
12. egistration 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 aliquid 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
13. fety 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
14. lant e 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 o
15. 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 e Plan inspection and testing activities on a periodic basis e Inspect and test as planned recording all results e Promptly initiate corrective action in the event of non conformance or malfunction of any equipment e 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 e 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 e Keep records of all maintenance work performed on the p
16. ne s normally required on a unit of certain size or type and must serve no other purpose but fuel cut off 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
17. oiler Safety Manager when the plant is occupied or unoccupied and the Boiler is in operation MAN 4000 03 2012 03 12 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 Figure 1 200 kW A1 A2 B1 50 kW A3 B2 B3 Public Assembly Buildings and Facilities may qualify ONLY under the risk assessed plant registration Program Plants wishing to operate under non continuous staffing levels must meet the capacity criteria and undergo an audit A plant audit does not guarantee reduced staffing levels Plants must maintain the same conditions as demonstrated in the audit in order to maintain their plant registration status Any changes to plant capacity operating hours certified personnel plant production and other variables must be reported to the British Columbia Safety Authority When changes do occur a new audit may be conducted in order to recertify the plant registration All plants will be audited on a periodic frequency to be established by the Boiler Safety Manager STAFFING LEVELS FOR RISK ASSESSED STATUS REFRIGERATION PLANTS Public Assembly Buildings Ice Arenas Curling Rinks Hospitals Schools and Colleges DER UN 200 KW A1 A2 B1 to 1000 kW 50 kW A3 B2 B3 to 1000 kW Over 1000 k
18. sses isse sena rne ssh ansa aan nna 8 High Level Alarm Suction Trap Non Critically Charged Systems esses 8 Ammonia Monitoring for Safety erame arai a ai a deaa aa aaa sss a nnns 8 Plant Audit Guideline 2 0 0 0 cece cece ec eccccececcccecececececesceceaeaueceatsueneaesuecestsuetsteneatsueneatans 12 PUDOS O e n carsianen tiation udatin ngs M 12 Tz MIDS 2E OVA eas ee atte bue eaten desde EUR MEL M LE ME m aie M eset dee d aC OE MEE 12 2 nO OO see seize ab ten sabe ita ai atte ite Mini datae tates e tipp dE ML M LL M EDD EA M DeL 12 23 ci inieizuediegqct 9 12 i NUAC CAIN ARP MM E 12 I ileiziszige dutem 12 6 Emergency Dreparedriess tosta etes ten b antheris fal La intl i eed eu eae 12 Doume gm UU mr 13 Yuug pdateM 13 LSS Rola CS seen ee ee ane eee ae ene eee ee ane RENDERE ERES 13 DEFINI ON O et Tc daian 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 effectiv
19. 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 CONTINUOUS STAFF STAFFING REQUIREMENTS REQUIREMENT POWER PLANT over 10 m STEAM HEATING PLANT over 30 m FLUID HEATING PLANT over 150 m LOW PRESSURE TFP over 150 m LT LP FLUID PLANT over 300 m AN UNFIRED PLANT over 150 m POWER PLANT up to 10 m STEAM HEATING PLANT up to 30 m FLUID HEATING PLANT up to 150 m LOW PRESSURE TFP up to 150 m LT LP FLUID PLANT up to 300 m AN UNFIRED PLANT up to 150 m POWER PLANT b w 10 to 30 m INSTITUTIONAL OR STEAM HEATING PLANT b w 30 to 200 m PUBLIC ASSEMBLY LOCATION FLUID HEATING PLANT b w 150 to 500 m FLUID HEATING PLANT b w 150 to 500 m LOW PRESSURE TFP b w 150 to 500 m LOW PRESSURE TFP b w 150 to 500 m LT LP FLUID PLANT b w 300 to 2000 m LT LP FLUID PLANT b w 300 to 2000 m AN UNFIRED PLANT b w 150 to 1000 m AN UNFIRED PLANT b w 150 to 1000 m GENERAL SUPERVISION STATUS PLANT OPERATION Minimum of a Power Engineer to attend site as required by the B
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