LMI/KgnSTPS/OD/OPS/SYST/009

Location Management Instruction

THE SAFE OPERATION AND MAINTENANCE OF

PULVERISED FUEL PLANT

Presented By:
Badri Vishal Agarhari
Anuj Saini
Scope of Presentation

 To describes safe operation and maintenance practices necessary to give an adequate

awareness and understanding in order to minimize the possibility of explosion and fires
occurring in and adjacent to P.F. plant

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Possible Sites of Pulverized Fuel Explosions

 Leakage of P.F. from the plant

 Careless cleaning up of deposits of P.F outside the plant

 The release to atmosphere of hot P.F fly ash containing a high concentration of unburnt carbon, such as

can occur at precipitator hoppers

 In Boiler Furnace

 Coal Bunkers

 Biomass pellet Storage and Conveyor Area

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 Fire incident in Mill Area

 In P.F pipe work systems and mills, the air/fuel ratio must change from very weak to normal, as the mill is brought
into service.

 The air/fuel ratios normally found in milling systems lie between 1.5/1 and 3.5/1. However, experience within the
industry shows that explosions cannot be sustained in mixtures where the air to fuel ratio is weaker than 5/1.

 An explosive mixture can also result during operation. Caused by:

 Loss of coal feed.
 Air ingress on suction mills.
 Faulty control or indication systems.
 Weak mixtures arising from manual control of air and/or fuel supply.

 It is also possible for accumulations of static coal to ignite, producing coal gas which, in the presence of air and an
ignition source, may explode.

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Abnormal fire in Boiler Furnace

 The accumulation of an explosive mixture in the furnace is an abnormal event. It follows failure
to ignite an accumulating cloud of fuel, or loss of ignition during operation.

 Partial loss of ignition can also occur, with potentially damaging consequences when re-ignition
occurs.

 Failure of the primary air supply to the mill, with the mill open to the furnace and continuing to
pulverize coal.

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Fire incident in Bunker

 Bunker associated with mills that are out of service are always in danger of spontaneous combustion

and shall be emptied if the plant is be off-load to an extended period

 Any ‘hot spots’ on the bunker of feeder wall shall be cooled by spraying with water.

 The coal in the bunker shall be maintained at a safe level

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Fire incident in Boiler Ash and Dust hopper

 Unburnt pulverized fuel being caught in ash or dust hoppers in significant quantities, the hoppers shall
be cleared immediately

 The release to atmosphere of hot P.F fly ash containing a high concentration of unburnt carbon, such
as can occur fire at precipitator hoppers.

 Bottom deashing timing should be monitored and sample of unburnt present in bottom ash to be
checked.

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Fire incident in Biomass Pellets

 There are two types Biomass of pellets:

a. Non torrefied biomass pellets
b. Torrefied biomass pellets

 Moisture affinity of non-torrefied pellets is very high so generally torrefied pellets are used in P. F. mills.

 Pellets have got very high amount of volatile matter hence highly inflammable.

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Safe Operation Practices

 Stabilize the ignition support before starting of mill.

 Maintain Minimum 50 TPH air flow for 5 minutes to purge out the mill.
 Milling systems shall not be put into service if a fire is suspected in any part including the coal feeder or
bunker.
 Excessive temperature of pulverized fuel in the mill shall be avoided, and should not be allowed to exceed
a temperature of 90°C.
 The velocities in the P.F. pipes on a running mill shall be sufficient to minimize deposition of fuel and be
above 15 m/s or above or as specified by manufacturers.
 Ensure the auto operation of Mill Reject Handling System.
 Keep standby mill temperatures as low as possible.

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Checklist for Safe Mill Operation

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Safe Operation Practices During Use of Imported Coal

 Blending of imported coal should be done preferably at top mill.

 Mill Loading to be limited considering the maximum loading .
 Ignition support for mill should be taken into service.
 Mill Outlet temp. to be limited below 70° C to avoid mill fire Coal pipe fire due to high volatile
matter content.
 Mill outlet temp. should not go below 60° C. If due to high moisture of coal temp. goes below 60°
C, then mill firing to be reduced to maintain the outlet temp.
 During imported coal firing, APH outlet flue gas temp. may rise hence monitoring and recording of
the same is necessary to avoid ID fan tripping on high flue gas temp.
 Wall blower and LRSB should be operated as per schedule.

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Checklist for Imported Coal Firing

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Actions to be taken During Mill fire

 When a fire is detected in the mill body or classifier and does not appear to be in mechanical danger,
increase coal feed to the maximum practicable with the coal feeder on manual control. Increase cold
air flow to the maximum practicable. Run like this for a period specified in the P.F Operating
Instructions, and then reduce coal feed to normal.

 If the fire persists, or the mill is in mechanical danger, or the coal feed is lost, withdraw personnel
form the area and prepare to shutdown the mill system.

 Evacuate the incident area and ask the operators to gather at assembly point.

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Safe Operation Practices During Use of Biomass Fuel

 During Biomass pellet firing, mill inlet temp. should be limited to 180°C.
 Storage area to be predefined and proper barricading is to be ensured. No cutting and welding
works should be carried out near that area. Area should be clearly demarcated as “No smoking
Area”.
 Conveyor firefighting system should always be healthy as the fuel is highly inflammable; hence all
protection needs to be healthy.
 Storage area should have proper firefighting provisions like hydrants and water monitors.
 Material Safety Data Sheet for these pellets are to be displayed near the storage area

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