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Furnace Explosion in CFBC Boilers PDF
Furnace Explosion in CFBC Boilers PDF
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.
As regards CFBC boilers, these are comparatively newer generation of
technology and explosion avoidance measures are not clearly understood by the
operating engineers.
In view of above and on the requests received from a number of CPP units, this
Instruction Write Up has been prepared for the benefit of the concerned.
2. Type of Explosion in CFBC Boilers
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.
3. Definition of Dust Explosion
A dust explosion is the rapid combustion of a dust cloud. In a confined or nearly
confined space, the explosion is characterized by relatively rapid development
of pressure with flame propagation and the evolution of large quantities of
heat and reaction products. The required oxygen for this combustion is mostly
supplied by the combustion air.
The condition necessary for a dust explosion is a simultaneous presence of a
dust cloud of proper concentration in air that will support combustion and a
suitable ignition source.
Explosions are either deflagrations or detonations. The difference depends on
the speed of the shock wave emanating from the explosion. If the pressure
wave moves at a speed less than or equal to the speed of sound in the
unreacted medium, it is a deflagration; if it moves faster than the speed of
sound, the explosion is a detonation. The term dust is used if the maximum
particle size of the solids mixture is below 840 m.
Minor flue gas explosions are called puffs or blow backs.
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.
6. Causes of Furnace Explosion
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
7. Basic Philosophy of Explosion Prevention
The basic principles of avoidance of explosion are:
v Fuel should never be fed into the furnace continuously for more than 12
Operation Sequence
Precondition -1: Bed temperature> 7600C
Same as above
Precondition -2: 6500C
< temperature />
a. Load carrying oil burners, if provided, should be switched on to increase
the temperature while following the procedure described under Restart
after a trip out.
b. Boilers not equipped with load carrying burners to follow the same
procedure described under Restart after a trip out. A very high degree of
vigilance is needed for establishing the ignition.
Precondition 3: Bed temperature < 6500C
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.
C. Cooling of Boiler following a Tube Leakage
The steps a) to g) will be the same as given above.
Instead of step h) cooling of furnace will be completed after burning the
coal already present in the furnace without feeding any additional coal.
Additional steps/ precautionary measures need to be taken are:
o When the tube leakage is at a location wherefrom water/ steam is
impinging on the bed, the bed will quench down. The fall in bed
temperature will depend on the magnitude of tube leakage.
o Fluidization to be attempted very carefully if bed temperature and
freeboard temperature are well above 7600C. Time lag allowed between PA
fan starting and its tripping (when combustion fails to occur) in this case
should also be 12 seconds.
o If proper combustion is not achieved in a couple of attempts, it is
advisable not to try any more. Allow bed to cool down while continuing with
purging operation. Cooling will be fast due to water falling on it from the
leaking tube. It may please be noted that allowing the bed to cool down on
its own will never invite explosion since fuel in suspension can only cause
explosion (refer explosion pentagon above).
o Never attempt to fluidize the bed when tube leakage has caused bed
temperature to fall below 7600C because the prevailing adverse condition in
the furnace in such case may quickly take out the heat energy from the air
and bed temperature may fall down to disastrous level of 5400C or below.
Allow bed to cool with purging on and drain out the bed when cool.
10. Protection of Boiler against Explosion
Explosion doors/ vents of adequate sizes and at suitable locations must be
provided in any type of boiler to mitigate the impact of explosion. Boiler
manufacturers may please be asked to provide the same.