Académique Documents
Professionnel Documents
Culture Documents
AND PROTECTION
1. Background :
A few CFBC Boilers have suffered furnace explosion in the past. Apart from
causing severe losses to the businesses concerned, the occurrences have shaken
the confidence of CPP professionals. Due to inherent characteristics, Pulverized
Fired (PF) boilers are more prone to such type of explosion than a CFBC
version. However, with an operation history of centuries, the general principles
necessary to avoid these dangers of PF boilers are clearly established and our
power plant personnel working in PF boiler based units are well versed in the
subject.
Most of the explosions faced in CFBC boilers are dust explosions caused by
small particles of coal in the bed and in the free board kept under suspension
by fluidizing air fans. However, explosion due to FO/ HSD/LDO used in duct
burners and/ or load carrying burners has also been reported.
Remembering the three sides of the fire triangle (fuel, heat, oxygen) and the
five sides of the explosion pentagon (fuel, heat, oxygen, suspension,
confinement) is important in preventing fires and explosions at any facility. By
eliminating the possibility of either suspension or confinement, an explosion
cannot occur, but a fire may occur. By eliminating the fuel, the heat, or the
oxygen requirements, neither a fire nor an explosion can occur.
Fuel
5. Explosiveness of Coal
· Volatile ratio
The volatile ratio is defined as the volatile matter divided by the summation of
volatile matter and fixed carbon of the coal. It has been determined that coals
with a volatile ratio exceeding 0.12 present a dust explosion hazard. All
bituminous coals fall into this category.
· Particle size
The particle sizes that can contribute to an explosion are 840 microns (0.84
mm) and below. Lesser the particle size more severe would be the explosion.
Hence PF boilers are more susceptible to explosions.
· Quantity
The minimum concentration of dust in suspension that will propagate a coal
dust explosion is called Minimum Explosive Concentration (MEC). The MEC for
bituminous coal is approximately 100 grams per cubic meter.
The upper explosive limit of coal dust concentration is 380 grams per cubic
meter that would propagate a low-velocity explosion.
· Heat
Furnace explosions in CFBC boilers are rare when both bed and free board
temperatures are above 760degC. Chances of explosions are very high when
these temperatures are below 540degC. Though not fully established, yet
chances of explosions can not be ruled out when bed temperature remains
between 540degC and 760degC.
a. Pushing the fuel (coal or oil) into the boiler when there is loss of ignition
known as ‘Delayed operation of Fuel Trip Relay’. Loss of ignition in a boiler
causes explosive mixture to form. Such mixture must be purged out before
initiating firing.
b. Sudden firing after a boiler is banked or stopped for a short period without
proper purging
c. Insufficient purging of the furnace
d. Unbalanced fuel air ratio to allow the fuel concentration to fall within
explosive range.
e. Leaking fuel supply system
ü Tripping of PF boiler with fuel supply shut off would result in complete flame
failure (barring slag burning). This may not be true in case of a CFBC boiler
where coal on bed may continue to smolder.
ü Failure of flame or complete loss of ignition in PF boiler immediately gives
the indication that any fuel supply under such condition would form explosive
mixture. Since loss of complete/ partial ignition can not be ascertained in CFBC
boiler (due to non- availability of flame sensing device), it becomes extremely
difficult to judge whether such mixture is being formed or not.
ü Incorporation of furnace safe guard systems in PF boiler which completely
shuts off the fuel supply when actuated by flame sensing device greatly helps
operation staff in preventing explosions. CFBC boilers are not fortunate in this
regard. In this boiler, even after stopping the fuel supply, coal on the bed
continues to remain present in the furnace unless boiler is cooled and those
materials are taken out.
ü The only parameter that would indicate whether combustion is being
established in a CFBC boiler is the reducing oxygen / increasing CO2 % in flue
gas at furnace outlet.
Operation Sequence
I. Stopping & Purging
a)
ü Ensure that coal feeders and oil burners stop immediately.
ü Continue to run the ID fan with adequate furnace draft for 15 minutes.
ü Start Secondary Air Fan (fan meant to supply combustion air over the
bed) and purge the furnace at least for 5 (five) minutes with a minimum of
25% of rated air flow.
ü Open the dampers in air/flue gas circuits during purging so that any
accumulation of explosives is driven out through ID Fan.
ü Ensure that air flow to siphons (from PA fan or Roots blowers) is
established.
ü The vent line and dampers in air inlet and outlet paths of bed ash
coolers (those cooling the ash with primary air) must remain open during
purging and then can be closed.
a. View through peep holes before fluidization to make sure that coal is
burning
b. Ascertain that all personnel are at safe distance from the boiler furnace
c. Fluidize the bed and watch carefully that oxygen % in flue gas at furnace
outlet starts dropping, an indication that combustion is getting established.
d. If within 12 seconds, the oxygen content in flue gas does not come down
then trip the PA fan and restart purging as described above.
e. Time lag of 12 seconds above has been arrived at with the consideration
that the time taken by the coal dust to reach lower explosive limit in the
confined space would be more than 15 seconds.
f. Attempt to maintain excessive rich fuel air ratio is again a potential
hazard indicated by high level of CO2 or low level of oxygen in flue gas.
Never allow oxygen %age to fall below 2.5 %.
g. Purging and restarting in above manner to be continued till fire in boiler
is established.
h. Feed coal and adjust air as per normal operation. It is assumed that the
control room/ shift charge engineers are well experienced in normal
operation of plant and equipment.
a. Boilers not equipped with load carrying burners are normally provided
with hot gas generators wherein oil is fired and resultant flue gases are
admitted into the furnace. When bed temperature drops below 6500C,
heating of bed must be done by firing hot gas generator.
i. As bed temperature rises, keep constant watch on oxygen % in flue gas
because rapid drop in this parameter will indicate that coal has caught fire.
Never allow oxygen %age to fall below 2.5 % .
b. Adjust promptly the recommended air fuel ratio when coal starts
burning.
Note:
A well structured control logic incorporating above particulars with suitable
interlocks can be provided in the process cycles so that human errors during
such situation can be avoided altogether.