COAL MILL EXPLOSION

CRITICAL CONTROL MANAGEMENT

July 2023
AGENDA

1. Objectives of the Training

2. Review of critical incident caused by Coal Mill Explosion
3. Critical Control Management – Coal Mill Explosion

2
Training objectives

1. To raise awareness about potential risks and hazards caused by Coal Mill
Explosion
2. To understand the key measures and practices to eliminate and /or
control these risks
 Introduction
Why focus on Coal Mill Explosion?
Coal Mill Explosion can cause FATALITY

4
 CRITICAL CONTROL #1 CRITICAL CONTROL #2

HAZARDOUS AREA MANAGEMENT DAMPER, FAN AND MILL SYSTEM TRIP

CRITICAL CONTROL #3 CRITICAL CONTROL #4

INERTIZATION EXPLOSION VENTS & FIRE FIGHTING

Hazardous Areas Management

• Area and equipment marked with ‘explosive

atmosphere (Ex) and hazard signage

• Required inspections completed and

maintenance carried out

• Access controlled and hot work prohibited

Hazardous Areas Management
Q ) Specific objectives of the Priority Unwanted Event (PUE):

Having the area appropriately classified into corresponding ‘Hazardours Areas’ as per ISO/IEC

60079-10-2, and hence minimizing the ignition sources by having the appropriate equipment and

access control to prevent an explosion

Q) What are the Critical Control Performance Requirements:

a) Hazardous Area Classiffication (HAC) drawings with appropriate equipment selection (e.g
ATEX certified, IECEx certified or NEC/CEC)

b) Regular inspection and maintenance of all equipment within the hazardous area that could
potentially lead to explosion (Detailed, Close and Visual Inspection)

c) No Hot Work allowed within Hazardous area unless the area has been declassified, and
Hot Work Permit (HWP) issued

d) Colored or tagged as “Hazardous Area” in the field. (Ex)

e) Access restricted, with appropriate signage

Q) What is the Critical Performance trigger for shutdown, critical control review or investigation?
15% Failed Certified Equipment during Inspection, Unauthorized deferment of maintenance
without Plant Manager’s written authorization
Damper, Fan and Mill System Trip

• Operator aware of critical limits and correct

response for sensors, alarms and interlocks
• Periodic ‘end-to-end’ trip testing carried out and
recorded in maintenance management system
• Safety-critical equipment is color coded or
tagged uniquely identified in the maintenance
system
Damper, Fan and Mill System Trip
Q ) Specific objectives related to the Priority Unwanted Event (PUE)

Early detection of change, and prevent the formation of an explosive atmosphere that could potentially
lead to an explosion

Detect the change in the process condition/parameters of Temperature, CO level and trip the booster
fan (suction), coal mill, and isolate baghouse by slam shutting the dampers

Q) What are the Critical Control Performance Requirements:

a) Pre-determined safe operating limits with high-level alarm and high-level trip on
Temperature and CO

b) Control system elements – Temperature transmitter, CO analyser, dampers proximity

switches, and damper magnetic release mechanism are periodically calibrated, along with
suitable preventive maintenance (PM) schedule and free of build up or any obstruction

c) Periodic ‘end to end’ Trip testing (minimum once a year)

d) Colored or tagged control system elements as “Critical Control” in the field

Q) What is the critical control performance trigger for shutdown, critical control review or
investigation

(a) Failed trip

(b) Unauthorized deferment without Plant Manager’s written AuthorizationIf any trip system is
overridden or disabled
Inertization
• Manual valves are locked open and inert
medium (CO2 or N2) tank is full

• Operator is aware of auto and manual

inertization and related hazards
• Inertization system is always active when mill
firing system is in operation
Inertization
Q) What are the specific objectives related to the Priority Unwanted Event (PUE)?

Early detection of change in process parameters such as Temperature and CO level, and automatically initiate the inertization
sequence to prevent the formation of an explosive atmosphere by having an inert atmosphere (either N2 or CO2) that could
effectively achieve a minimum of 20% below Limiting Oxygen Concentration. Provision of a manual inertization from the Central
Control Room (CCR) if a fire or smouldering detected by a passerby

Q) What are the critical performance requirements to meet the objectives?

a) Pre-defined Solenoid Valve opening position with a high-level trip on Temperature and CO

b) Control system elements – Temperature transmitter, CO analyser, Solenoid valves are periodically calibrated, along with
a suitable preventive maintenance (PM) schedule and free of build-up or any obstruction

c) Periodic ‘end-to-end’ Trip testing (minimum once a year)

d) Instruments and equipment associated with inertization systems are colored or tagged as “Critical Control” in the field

e) All manual isolation valves are locked open or the valve handles are removed at an open position

f) Inert medium(N2 & CO2) maintained full in the tanks

Q) What is the critical control performance trigger for shutdown, critical control review or investigation?

a. Failed inertization upon testing

b. Unauthorized deferment without Plant Manager’s written authorization

Explosion Vents and Fire Fighting
• All explosion protection and firefighting systems
are rated, certified and maintained
• Access restricted and zone barricaded in the
explosion vent area
• Firefighting system performance is tested annually
and regular drills conducted
Explosion vents and Fire Fighting
Q) What is the specific objective related to the Priority Unwanted Event (PUE)?

a. Having appropriately designed explosion vents as per ISO/EN 14491, and fire fighting systems

b. Prevent any catastrophic explosion due to confinement and secondary explosion. Limit the
extent of the damage and further propagation

Q) What are the critical performance requirements to meet the objective?

1) Certified explosion protection devices rated for the (maximum pressure, Pmax, pressure rise
during explosion, Kst, and Reduced pressure due to explosion venting, Pred values of coal in
use)

2) Regular inspection and maintenance of all explosion protection devices free of any build-up

3) Regular inspection, testing and maintenance of the fire fighting system (Reels, hydrant, hose,
fixed cannons)

4) Colored or tagged as “Critical Control” in the field, Explosion vent zones need to be barridcaded
and access restricted

Q) What is the critical control performance trigger for shutdown, critical control review or
investigation?

Failed/inadequate Certified Equipment during inspection

Unauthorized deferment without Plant Manager’s written authorization