LBNG QSK60G & QSK60G - High
Efficiency Series Gas Engines
Module 3 - SAFETY
Cummins Corporate Training
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Safety
Learning Objective
Participants will understand the need for performing Risk Assessments and
demonstrating “due diligence”. You will be aware of the different types of work
permits required, as well as other general safety requirements. You will also
understand the need for and be able to demonstrate good engine lock-out
procedures. In addition, you will have an awareness of electrical safety.
Agenda
• Engine Information Labels. • Natural Gas Properties.
• Risk Assessment. • Leak Detection.
• Work Permits. • Safety Rules.
• Commons Electrical Safety. • Engine Lockout Procedures.
INFORMATION CONTAINED WITHIN THIS TRAINING PROGRAM DOES NOT
OVERRIDE OR REPLACE LOCAL SAFETY LEGISLATION OR REQUIREMENTS.
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Engine Information Labels
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Risk Assessments
A MUST before any work commencement to provide safe working at all times.
• Performed by a competent person with authority to implement the required safety
measures:
• Job Planning (people + place + tools + time)
• Personnel Selection (Required Skills Definition)
• Adequate Work Space & Lighting
• Method of deactivating the equipment
• Can you prove that the equipment is isolated / dead?
• If working on live equipment, question why:
• Is the risk reasonable?
• Can the task be accomplished on isolated / dead equipment at some other time?
• Is the right PPE available at the work site?
• If the risk assessment is conducted by someone other than yourself – perform your
own risk assessment & keep a record.
When working strictly adhere to & enforce the mitigation tasks
resulting from the assessment.
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Work Permits
Almost always required before even visiting a site!
Required Personnel Permit Types:
Access: Not undertaking work on plant equipment (cleaning, painting, etc.)
Work: Routine service / maintenance / repair tasks on plant equipment
Note: Separate permits required for HV systems lock-out.
Hot Work: Naked flames / heat generating equipment required in plant.
Sanctioned to Test: Energized systems required for tests by means other than its
normal source, e.g. MEGA. Also allows for the removal of safety devices for
purpose of testing.
Confined Space: Tasks in confined spaces with risks of fume accumulation, etc.
Obtain these permits from the plant or plant safety supervisor before departing to
5 work on site.
QSK60G / Safety / KDL / April 2010 / REV 1.01.
Common Electrical Safety
Final Work Safety Precautions
Always isolate and lockout the electrical supply
– Display isolation notices
Only work on apparatus that you are authorised to
Follow local safety rules & permit to work systems
Keep one hand in your pocket when working with electrical equipment to
prevent accidental contact with ‘live’ or ‘earthed ’ components.
Ensure all electrical cables are:
– Properly Supported
– Protected Against Shocks + Stresses + Abrasion
– Using flexible or solid cable trunking and / or cable ties
If in doubt - DON’T DO IT, ASK!
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Typical Electricity Grid
Supply Ratings
400,000 Volts (EHV) (Recommended safety radius 3.1m)
275,000 Volts (EHV) (Recommended safety radius 2.4m)
132,000 Volts (Recommended safety radius 1.4m)
66,000 Volts (Recommended safety radius 1.0m)
33,000 Volts (And below, recommended safety
radius 0.8m)
11,000 Volts
High Voltage Voltage
1,000 Volts Low Voltage Classification
0 Volts Ground Potential
DANGER! High voltage will jump large distances to any part of your body or ground conductor.
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
ELECTRICAL SAFETY
AMPERES SEVERE BURNS 6 AMPS TO A
1.0A SOLENOID!
BREATHING STOPS
DEATH
0.2A
200mA DIFFICULT
HUMAN BODY
BREATHING RESISTANCE
0.1A APPROXIMATELY
100mA 5,000 ohms
OUCH! SAFETY VOLTAGE IS
IT TINGLES CONSIDERED AS 50V.
0.04A THIS WOULD RESULT
40mA IN A MAXIMUM
Possibility of CURRENT FLOW
0.001A
DEATH THROUGH THE BODY
1mA OF:
CAN JUST FEEL IT
50/5000 = 0.01A (10mA)
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Natural Gas Properties
3 TIMES LIGHTER AS LESS
DENSE
PROPANE & OTHER
COMMONLY
NATURAL GAS
IN BURNED FUELS
COLOURLESS
ODOURLESS
AIR
FALL
RISES
NOTE: Manufacturers and Utility companies add odorants which gives
natural gas it’s familiar scent. This does not mean that safety devices such
as methane detectors are unnecessary.
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Natural Gas Combustion
Window
LEL UEL
4% 16%
NATURAL GAS VOLUME IN AIR
LEL = Lower Explosive Limit UEL = Upper Explosive Limit
Natural Gas is ONLY flammable when mixed with oxygen
to a certain level. Natural Gas must make up 4.0 to 16.0
percent of the volume of air.
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NATURAL GAS
SAFETY RULES - RECAP
• Natural Gas is THREE TIMES lighter than air.
NATURAL GAS
COLOURLESS
• Natural Gas is COLOURLESS and ODOURLESS. RISES
ODOURLESS
• Suffocation Occurs above 7 parts Gas to 1 part Oxygen.
• Typical Pipeline Natural Gas is approximately 90% METHANE.
• Natural Gas has a Combustion Window of 4% - 16% by volume of air.
LEL UEL
4% 16%
• Only use the correct fire extinguishers (CO2 or Dry Powder).
• REMEMBER! The engine will perform a ‘VENT CYCLE’ on the next start attempt
following any E-STOP.
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Leak Detection
Methane gas detector MUST be
available to check pipes and fittings.
Always place detector ABOVE the
fitting being tested to ensure methane
is detected.
Use Soap & water solution to pin-
point location if necessary.
If leak detected or hazard exists, shut
off supply and ISOLATE all potential
ignition sources. NOTE:
Ventilate the area. Natural gas is non-toxic, however,
in a ratio of seven parts or more to
Display GAS HAZARD! sign. one oxygen, suffocation occurs
(same for all gases).
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Safety Rules
You must be aware of and work to local H & S and Gas Council rules,
these vary dependant on each country or area.
It is your responsibility to comply.
Any work carried out on the engines gas system MUST be undertaken by a
competent person who is registered with a body such as Gas Safe before
putting into service.
Examples of such governing bodies are;
United Kingdom:
Gas Safe (formally CORGI Council for
registered Gas installers).
ACOPS (Approved Codes of Practice laid
down by the HSE).
USA:
AGA (American Gas Association).
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Safety Rules
In a lean burn engine installation, gas may cause DANGEROUS situations.
The most serious situations are:
1) Gas leaks into the engine room.
2) Gas fires & explosions caused by unburned gas in the exhaust system.
For these reasons it is important that:
1) The installation includes high level gas detectors connected to an alarm
system.
2A) The engine starting system includes an automatic crank cycle without gas
to purge any gas from the exhaust.
2B) A high quality safety exhaust system is installed. This would include
pressure relief valves that relieve system pressure while channeling un-
burnt gasses and combustion products to a safe open area in the event of
an explosion.
ALWAYS FOLLOW LOCAL FIRE AND SAFETY CODES
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Safety Rules
Fire Extinguishing
Remember to shut-off supply at source!
Use Carbon Dioxide or dry powder extinguishers
only - starve fire of oxygen.
CO 2
Gas Detectors
Trouble-shoot for leaks by soaping suspected
locations or probing with hand held gas detector.
Larger leaks may be detected by sound or
“frosting” - Never use an open flame!
Installations should be fitted with combustible
gas detectors at high level and connected to the
alarm system.
ALWAYS FOLLOW LOCAL FIRE AND SAFETY CODES
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Safety Rules
Ignition Sources
Do NOT light matches or smoke cigarettes.
Do NOT use electrical equipment that is
not approved for use near flammable gases.
Hot surfaces are less of a danger for natural
gas than other fuels but may still cause ignition
(Auto - ignition temp; NG = + 480º C, Gasoline = 100º C).
Ventilation
Always work in a well ventilated area and outdoors if possible.
Rooms and enclosures must be well ventilated, use high level extraction fans,
ensure the heating systems is not open flame type.
ALWAYS FOLLOW LOCAL FIRE AND SAFETY CODES
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Engine Lockout and Tag out
Before Working on the Engine:
Consult with the Owner/Operator to fully isolate any Automatic or Remote Start
devices.
Consult with Owner/Operator to isolate Generator system and any associated
devices.
Remove any keys and follow the lockout / tag out procedures for the equipment
being worked on. This may include:-
Electrical Supply Switches. Engine starting batteries
Disable remote start capability
The gas supply.
Engine heaters as required.
Isolate the engines 24-VDC supply system.
Display isolation/caution notices at all relevant locations.
ALWAYS FOLLOW LOCAL FIRE AND SAFETY CODES
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QSK60G / Safety / KDL / April 2010 / REV 1.01.
Conclusion
Gas engines are
nice babies but take
care of them to
avoid…...
....emergency cases!
CAN YOU REMEMBER THE BASIC
PROPERTIES OF NATURAL GAS?
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Team Task
Show you know..
Rules of Natural Gas Safety
1. Identify the common properties of Natural Gas…
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QSK 60G & QSK60 - High Efficiency
Series Gas Engines & Gensets
Module 3 - SAFETY
End
Cummins Corporate Training
20
HE -60G/
QSK60G Intro // BMG
/ Safety KDL // April
03 - 07 / REV
2010 01. 1.01.
/ REV