EXPLOSION OCCURANCE IN CFBC BOILER AND NECESSARY

OPERATIONS
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.

1. 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
un reacted 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.

2. Fire Triangle and Explosion Pentagon

There are three necessary elements which must occur simultaneously to cause
a fire: fuel, heat, and oxygen. These elements form the three legs of the fire triangle.
By removing Fuel any one of these elements, a fire becomes impossible. For Fire
Triangle example, if there were very little or no oxygen present, a fire could not occur
regardless of the quantities of fuel and heat that were present. Likewise, if
insufficient heat were available, no concentrations of fuel and oxygen could result in
a fire. On the other hand, for an explosion to occur, there are five Air or Oxygen
Suspension necessary elements which must occur simultaneously: fuel, heat, oxygen,
suspension, and confinement. These form the five sides of the explosion pentagon.
Like the fire triangle, removing any Ignition Source one of these requirements would

prevent an explosion from Confinement propagating. For example, if fuel, heat,

oxygen, and confinement occurred together in proper quantities, an explosion would
still not be possible without the suspension of the fuel. However, in Fuel this case, a
fire could occur. If the burning fuel were then placed in suspension by a sudden blast
of air, all five sides of Explosion Pentagon the explosion pentagon would be satisfied
and an explosion would be imminent. 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.

3. Causes of Furnace Explosion

a) Dumping 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

4. Basic Philosophy of Explosion Prevention

The basic principles of avoidance of explosion are:
i)
ii)
iii)
iv)

Fuel should never be fed into the furnace continuously for more than 12
seconds when there is no fire.
Furnace is completely purged of the explosive mixture and then fired.
Fuel supply is stopped immediately if fire/flame is not established and repurging is surely done before restart.
Correct air fuel ratio is maintained so that dust concentration within
explosive limits is never achieved.

5. Difference between a PF Boiler and a CFBC Boiler

Following aspects need to be considered before sequencing the operation of a CFBC
Boiler:

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.
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 cannot 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.
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.
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.

6. Operation to Prevent Explosion in CFBC Boilers

The explosions mostly occur when
Boiler is restarted after a trip out.
Boiler is restarted after a short period of stoppage
Fast cooling of boiler is resorted to following a tube leakage especially when
the leaking water falls on the bed
Major operation steps recommended to be followed to avoid any risk of explosion
in such cases are
A. RESTART AFTER A TRIP OUT
Precondition: Bed temperature in this case will remain above 7600 C.

Operation Sequence
I.

II.

Stopping & Purging

Ensure that coal feeders and oil burners stop immediately.
Continue to run the ID fan with adequate furnace draft for 15
minutes.
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.
Open the dampers in air/flue gas circuits during purging so that any
accumulation of explosives is driven out through ID Fan.
Ensure that air flow to siphons (from PA fan or Roots blowers) is
established.
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.
Fluidizing the bed by PA Fan & Fuel Charging
This is the most vulnerable operation requiring a high level of competence
and skills of the engineers and operators.
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.
B. RESTART AFTER A SHORT PERIOD OF STOPPAGE
Caution:
Purging with SA fan and ID fan should continue since bed contains
smoldering coal
PA fan to be stopped to avoid bed temperature falling sharply.
Operation Sequence
Precondition -1: Bed temperature> 7600C
Precondition -2: 6500C <="" 7600C=""
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.
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:
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.
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.
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).
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.

7. 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.
Opportune test must be carried out periodically to ensure that the explosion vent
/door are perfectly operational.