Recommended

Best Practice

COAL BUNKER, SILO &

HOPPER
WHAT THIS PRESENTATION IS NOT:
A TRAINING SESSION ON STRATEGY & TACTICS

WHAT IT IS:
AN OVERVIEW OF THE BEST PRACTICE DOCUMENT

WITH THAT IN MIND………….

PEER REVIEW PROCESS
technical review by utility
fire protection experts
REVIEW COMMITTEE:
Jim Beller: AEP
Jim Coco: Marsh, Inc.
Eric Dorbeck: Consumers Energy
Jim Ritter: Pacificorp
C.E. Wilson: Southern Company
Ed Douberly: Utility FPE Group, Inc.
Norm Rockwell: TVA
History Of The Practice
January 2001
Proprietary Procedure from
TVA
(Tennessee Valley Authority)
Slightly Revised
Contained Identifiable TVA
References
Published As A Procedure
Contained Product Names
January 2003
Used Original Document As A
Basis For Review
Revised To The Extent Of A
Being A New Document
Removed All References
Published As A Guideline
Generic Product Reference
Coal Bunker, Silo & Hopper Fire
Protection Guidelines
TABLE OF CONTENTS
1.0 Introduction
2.0 Scope
All New
3.0 Fire Prevention and Detection
4.0 Fire Protection Equipment & Training
Revised 5.0 Fire Fighting
6.0 References
Appendix
 Section 1.0
Introduction
– Reliance on this guideline without the
proper training, equipment, and
planning is irresponsible.

– No liability is assumed by the PRB Coal

Users’ Group, its directors, officers or
members or The TradeFair Group, Inc. for
its use. Proper training, equipment and
planning assistance are readily available in
the commercial market.
market
 Section 1.0
introduction
z The Paper Recognizes 2 Important Issues:

1. The majority of plants burning or converting

to PRB were not designed to accommodate its
characteristics.

2. Not all plants are prepared to deal with fire

through the use of an on-site structural fire
brigade.
 Section 1.0
introduction

z PURPOSE

To Assist In Establishing Safe Operating

Practices That Efficiently And Effectively
Controls And Extinguishes Fires And
Minimizes Impact On Plant Assets For Fires
That Ignite In Coal Bunkers, Coal Hoppers
or Silos.
TRANSLATED:
This is the best advice we have to offer based on what we know at the present time…
 Section 2.0
scope
z All plants burning or converting to PRB in
pure or blended amounts

z Facilities vary widely in design.. bunker/silo

fires must be delt with individually

z Circumstances effecting prevention, detection

and extinguishment very widely

z No “One Size Fits All” procedure

z Fundamental principals & equipment are the

same and can be adapted for most needs
 Section 2.0
scope

z Provides Guidelines & Information in 3

Important Areas:
¾ Fire Prevention & Detection

¾ Fire Protection Equipment &

Training

¾ Fire Fighting
 Section 3.0
fire prevention & detection
the prevention of fire and explosion is the
foremost objective while utilizing PRB coal.
Prevention can be accomplished through the
following…

z Presented In 4 New Sub Sections

– 3.1 Housekeeping
– 3.2 Preplanning
– 3.3 Bunker and Silo Design
– 3.4 Fire and Gas Detection
 Section 3.0
fire prevention & detection
z 3.1 HOUSEKEEPING
– Means dust control and spillage mitigation
z Transfer point containment

– suppressants, engineered chutes & hoods, misting

z Belt spillage
– Manual washdown with hose streams….
z Beneficial but generally not totally effective

under conveyors and in the overhead

z Labor intensive, safety issues

– Fixed washdown systems….

z Significant improvement over manual hoses

z Potential for 100% coverage

z Reduced labor costs

air borne spillage
 Section 3.0
fire prevention & detection
z 3.2 PREPLANNING
– Planned Outages
z Empty bunkers and silos
z Washdown interior of walls and structural members
z Use of micelle encapsulating agent beneficial
– Unplanned Outages
z Monitor for signs of spontaneous combustion
z CO monitors, thermography, temp scanning
z Don’t rely on visual or olfactory signs….by the time you
see or smell burning coal….the fire is already underway.
– Inerting of Idle Enclosures
z CO2 is an O2 displacer-helps prevent combustion
z Button up to prevent leakage…1.5 times heavier than air
z Here’s what you need: 3.3 lbs/ft3 to effectively inert
z For 22’ x 55’ silo that’s 3.2 tons
 Section 3.0
fire prevention & detection
z 3.3 BUNKER & SILO DESIGN
z Fires in Active Enclosures…shame on you
– Active enclosures should not experience fires under
normal operating conditions
– Fire in active enclosure…design irregularity
– Horizontal surfaces, weld cracks, rat holing
z Mass Flow….not the same as “Most Flow”
– Most important aspect in preventing fire
– Eliminate flat bottoms in bunkers
– Free flow though silo cones
– Evaluate lining….if its slick it shouldn’t stick
 Section 3.0
fire prevention & detection

FUNNEL FLOW MASS FLOW

Stagnant Zones
 Section 3.0
fire prevention & detection

Access
Ports At
Various
Levels

Eliminate Flat Bottoms In Bunkers

 Section 3.0
fire prevention & detection
z 3.3 BUNKER & SILO DESIGN
z Access To The Interior
– Most important aspect of successful
extinguishment….most difficult to achieve
– Preplan how you will get to a fire
z Side Access Ports
– Installed around accessible sides & various levels
– Successfully used with piercing type tool
z Top Access
– Manholes
– Equipment hatches
– Transfer chutes
– Tripper troughs
Flat Horizontal Surfaces
Bunker Access Port
 Section 3.0
fire prevention & detection
z 3.4 FIRE & GAS DETECTION
z CO Monitoring
– Earliest Warning of Combustion Before
Smoke or Odor
– Normal Background Levels Rise & Fall
– Look for Continuous Upward Trending
z Thermal Monitoring
– Plain Vanilla Heat Detection
z Infrared Thermography
– Visual Thermo Image-exterior & interior
– Excellent for Tracking Fire Fighting
Progress
z Methane Monitoring
– From Processing…Not combustion
– Most Prevalent In Coal Mined Underground
 Section 3.0
fire prevention & detection
z CO Monitoring
– Earliest Warning of Combustion Before
Smoke or Odor
– Normal Background Levels Rise & Fall
– Look for Continuous Upward Trending
– Best for Bunkers/Silos and Tunnels

z Infrared Thermography
– Visual Thermo Image-exterior & interior
– Excellent for Tracking Fire Fighting
Progress
– Can be Incorporated To Watch for
Combustion on Moving Belts
Actual silo fire taken with IR camera. The fire follows a
weld joint around the circumference. The fire vane is ~5’
thick and ~12’ below the surface of the coal.
 Section 4.0
fire protection equipment & training
Dealing with a fire in a bunker or silo is a
dangerous undertaking that must be
approached with the correct equipment and
training….

z Presented In 4 New Sub Sections

– 4.1 Fixed Hazard Mitigation Systems
– 4.2 Manual Fire Fighting Tools
– 4.3 Fire Extinguishing Agents
– 4.5 Fire Training
 Section 4.0
fire protection equipment & training
z 4.1 FIXED HAZARD MITIGATION SYSTEM
z Hybrid System
– Fixed piping system for Washdown/dust control
– Deliver fire extinguishing agent
– Not a fire suppression system in the classical sense
z Pros
– Immediate agent deployment
– Scrub the atmosphere
z Cons
– Entire contents subject to flooding
– May require zoning
– Water alone not sufficient
HYBRID SYSTEM INSTALLED
IN A BUNKER
 Section 4.0
fire protection equipment & training
z 4.2 MANUAL FIRE FIGHTING TOOLS
z Get directly to the FIRE
– Know the location…thermography
– Have Access….ports, hatches, etc.
– Have the proper tools

z Piercing Type Tool

– Manually maneuvered into place
– Lengthened by 5’ extensions
– Delivers agent directly to the fire
– Avoids the “surround and drown” approach
 Section 4.0
fire protection equipment & training
z 4.2 MANUAL FIRE FIGHTING TOOLS
z Fire Hose
– Requires Most Training to be Effective
– Most Dangerous Method
– Temptation to use Straight Stream to get to the
Fire…..Absolutely Avoid Drilling
– Stir up float dust
– Flash explosion in enclosure
– Secondary explosion outside the enclosure
– Adds significant water loading….more than
needed to extinguish the fire.
 Section 4.0
fire protection equipment & training
z 4.3 FIRE EXTINGUISHING AGENTS
Extinguishing Slow Mechanical Fast Fuel Molecule Free Radical
Agent Penetration Blanket Penetrant Encapsulator Interrupter

(air exclusion) (surface tension No current No current

reduction) NFPA or UL NFPA or UL
NFPA 1151 for index test index test
Class A Foams; NFPA 18
NFPA 11/UL 162
for Class B
Foams

Water X
Wetting X
Agent
Foams X X
Micelle X X X
Encapsulator
 Section 4.0
fire protection equipment & training
OTHER AGENTS
z
z CO2 and Nitrogen
–Ineffective for rapid extingushment
–Poor cooling capacities
–Lack of ability to hold proper concentrations

z Effectiveness Based On
–Fuel geometry
–Fire stage
–Enclosure tightness
–Application duration

THESE ARE THINGS ONE SHOULD NOT HAVE

TO BE WORRIED ABOUT DURING AN
EMERGENCY.
 Section 4.0
fire protection equipment & training

z 4.4 FIRE TRAINING

Use of this guideline is NOT a substitute for
formal and proper training in industrial fire
fighting
z Plant Personnel

z Outside Fire Department

 Section 4.0
fire protection equipment & training
z Plant Personnel
– Absolutely no participation without proper training
– Defined by OSHA 1910.156, Fire Brigade Standard
– Exempt municipalities should not use exemption to
avoid proper training
z What Is Proper Training?
– Structural Fire Brigade w/bunker-silo evolutions
– Incipient Fire Brigade w/equipment and evolutions
– Specialized Emphasis Training w/classroom,
equipment and evolutions
z The Key….
– To be properly trained for the hazards which they
are expected to confront.
z Outside Fire Department
– Excellent Knowledge of residential, commercial & light
industrial facilities
– Most are not prepared with the knowledge and training
for dealing with hazards in power plants
– ASK THEM…If they don’t know about PRB coal they are
NOT prepared
z What Is Proper Training?
– Same as for plant personnel
– Annual “walk throughs” are NOT adequate
– Plant sponsored specific training
– On-site drills with full equipment
z Get Them HIGH….get them trained on
– High Pressure, High Speed Rotation, High Voltage
– The Key….To be properly trained for the
hazards which they are expected to confront
 Section 5.0
fire fighting
z Presented In 3 New & Improved Sub Sections
– 5.1 Fire Fighting Equipment

– 5.2 Roles and Responsibilities

– 5.3 Instructions
z 3 Step Process
– Step 1: Develop An Action Plan
– Step 2: Prepare The Area
– Step 3: Fire Extinguishment

THIS JUST IN>>>>HAPPY HOUR IS JUST A FEW MINUTES AWAY…

 Section 5.0
fire fighting
z 5.1 FIRE FIGHTING EQUIPMENT
z Fire Hose & Nozzles
– Staple or most fire fighting
– Not adequate for safe & effective use on
bunkers/silos
z Tools Of Choice
– Piercing type tool
– Micelle encapsulating agent
– Infrared camera
z PPE
– Bunker gear
– SCBA if needed
 Section 5.0
fire fighting

z Piercing Type Tool

– Commonly referred to as a piercing rod
– Cone shaped piercing tip-spray pattern
– Extensions in 5’ lengths
– Diameters of ¾”, 1 ¼” , 1 ½”
– Horizontally or vertically
 Section 5.0
fire fighting

z 5.2 ROLES & RESPONSIBILITIES

z Plant Employees

z Fire Brigade Leaders

z Fire Brigade Team Members

z Outside Fire Department

 Section 5.0
fire fighting

z 5.3
INSTRUCTIONS
z Step 1: Develop An Action Plan

z Step 2: Prepare The Area

z Step 3: Go For It….Fire Extinguishment

 Section 5.0
fire fighting
z Step 1: Develop An Action Plan
z Unless left unchecked….you have time
z Perform heat survey
z Map the fire area
z Cease all coal moving activities
z Deal with it!!
z Don’t run it through
z Don’t smother with fresh PRB coal
z Determine access
 Section 5.0
fire fighting
z Step2: Prepare The Area
z Neutralize Dusting
– Prepare for blowback
– Washdown area
z Ventilation
– Gravity ventilate tripper/cascade room
– Dust collector: can cause explosion/acts as draft
inducer
– Dust collector Fog the headspace
z Stage Equipment
 Section 5.0
fire fighting
z Step3: Fire Extinguishment
z Spray headspace & surface
– Fog pattern of nozzle/piercing rood/cellar
nozzle
z Insert& work piercing rod to hot spot
z Monitor thermal imaging
z Prevent excessive water-use spotter
z Expect smoke, then smoke & steam, then
steam, then nothing (if all goes well)
SMOKE & STEAM
MOSTLY STEAM
NICE & CLEAN
 take a look at….
z Notes 1 and 2

z Appendix
– Prejob Briefing Checklist
– Job Safety Analysis Sheet
RAHM’S
BUY’N!!