Rockford Systems delivers trusted combustion safety solutions.

Since 1971, the Fortune 500 and many of North America’s largest manufacturers have depended upon Rockford Systems for turnkey safety solutions to bring their organizations into compliance with today’s regulations and standards, and to ensure they are prepared for what challenges may lay ahead for tomorrow.

With over 45 years of experience, Rockford Systems enhances the long-term health and quality of life of workers in high-risk occupations, while improving the bottom line of the organizations we serve by increasing compliance, reducing risk, lowering costs and improving productivity.

Demystifying Combustion Safety

Does your manufacturing facility have a smoke stack? If it does, your facility also likely contains a valve safety train, commonly known in industrial circles as a “gas train” or a “fuel train.” This complicated series of piping and components requires annual safety inspections, accurate record keeping, and preventive maintenance to avert serious safety and productivity issues.

If you aren’t sure what a valve safety train is, you’re not alone. Combustion safety systems are commonly one of the most misunderstood pieces of equipment on the plant floor. As a result, the valve safety train rarely receives the consideration it should from safety professionals.

While it isn’t necessary for a safety professional to know every engineered component of a valve safety train, you should be aware of what it does and why it demands your organization’s attention. Essentially, a valve safety train controls the flow of fuel into fuel-fired equipment used in thermal processing. By controlling the desired ratio of fuel and air, the connected burner may then safely oxidize the mixture, releasing the energy to heat furnaces, boilers, HVAC heaters, thermal oxidizers and other equipment. In turn, the thermal process equipment performs critical tasks such as drying gypsum boards, roasting and baking foods, heat-treating metals, fluid heating, and pollution control.

Owing to the presence of hazardous vapors and gases, poorly designed or inadequately maintained trains have led to catastrophic explosions, fires, asphyxia and burns, multi-million dollar loses, injuries and fatalities. Consider the calcium carbide plant explosion in Kentucky that killed two workers and injured two others, resulting from a failure by the company to properly maintain a large electric arc furnace that blew up in 2011.

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Annual Combustion Safety Inspections

Combustion Safety InspectionThankfully, you can significantly reduce the potential for accidents by conducting annual safety inspections on your organization’s combustion safety equipment. Learning about and acting upon the potential dangers of a valve safety trains and scheduling annual inspections helps reduce risk and improve safety in your organization. Find the valve safety trains in your plant and have a look at them. Can you find inspection documentation, such as stickers in the control box or other supporting paperwork? Do the test plugs look dirty and dusty on the shut-off valves? If you cannot find evidence of a recent annual inspection, have a conversation with your plant manager or maintenance team lead.

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Standard Valve Trains

Valve trains, or fuel trains, control the flow of gasses for industrial equipment, such as furnaces, ovens, dryers and boilers, making them a crucial component in assuring operational safety and energy efficiency. Rockford Systems’ valve trains feature industrial-grade construction and are universally wired to accept most North American control systems. Optional features allow for common adaptations such as safety valve proving, climates down to -20°F, 230V controls, lockable valves, and pilot-line assemblies. Standard valve trains are stocked and available in multiple sizes (1/2” to 2”) with capacities up to 7,500 SCFH, and pre-designed units with capacities up to 22,500 SCFH.

Customized Valve Trains

Rockford Systems also offers custom layout and designs for any capacity, fuel, footprint, or environment. Variations are quickly accommodated due to our standardization platform. All designs, whether standard or custom, feature industry-leading components, are engineered to meet or exceed NFPA, NEMA, NEC, CSA, UL, FM and other globally-recognized safety standards, and feature a two (2) year warranty.

All Rockford Systems industrial-grade components are ventless, wired to universally accept 50 or 60Hz control systems, and accommodate operating fuel and ambient temperatures anywhere from 14°F to 140°F. Optional features such as, lockable valves, valve proving, flexible compensators, pilot-line assemblies, 230V controls, and climatizing to -20°F, are also available.

Stallion Quick Ship Program

Rockford Systems offers best-in-class valve train delivery in days rather than weeks or months. To achieve delivery in days, rather than weeks or months, Rockford Systems offers an array of standardized valve trains that are pre-engineered, modular, assembled from existing segments, and importable as 3D models for customers’ CAD systems.

Please call 1-800-922-7533 or email to learn how Rockford Systems can help your organization improve industrial equipment safety through a comprehensive approach to combustion safety solutions today.