Summer, 2000 Volume 12, Issue 1

Explosion Protection in Pulverized Coal Processes

By Ralph Foiles, Fike Corporation The pulverization of coal to improve burning efficiency and maximize energy output is a method that has been used for more than 75 years. Pulverized coal processing and storage systems are typically found in power generation, steel and iron manufacturing, cogeneration, cement drying, and other industries that employ coal injection furnaces. Compliance with the Clean Air Act Amendments (CAAA) of 1990 has required reduced emissions of sulfur dioxide and nitrogen oxides. Compliance with Phase I of the CAAA was required January 1, 1995, where Phase II compliance is required on January 1, 2000. Many facility operators have accomplished compliance by simply switching fuels from high-sulfur bituminous coals to low-sulfur sub-bituminous coals of the Powder River Basin (PRB). However, considerable re-engineering of these facilities must occur along with the switch to PRB coal. One area of concern is the explosion prevention and protection systems. While switching to PRB coal addresses the environmental concerns, it unfortunately increases the degree of explosion hazard characteristics, compared to bituminous coals.
Dust Collector Coal from Bunker to Pulverizer

Storage Bin

To Furnace

1. The possibility of spontaneous combustion is more likely, due to lower auto-ignition temperatures and shorter auto-ignition times. (See Table 1) The explosibility index, KST, is usually higher. This means if a deflagration (explosion) occurs, PRB coal will experience faster rates of pressure rise and possibly require enhanced explosion protection systems to achieve the same level of safety compared with bituminous coal. (See Table 2)
Continues on page 2

Figure 1 Typical pulverized fuel storage and firing system

In this issue
Explosion Protection in Pulverized Coal Processes .........................1 API RP520 ...................................3 Water Mist Benefits .....................4 New Explosion Detector ...............5 DisCalc 2.10 Software ..................6

Continued from page 1

Protection Solutions Explosion protection strategies include both preventative and responsive methods. Preventative strategies, such as inerting and carbon monoxide (CO) monitoring, are primarily directed at decreasing the probability of the occurrence of an explosion. Preventative techniques seek to eliminate one of the ingredients of an explosion (suspended fuel, air, or ignition source). Preventative methods are not 100% effective. An explosion can occur by means of a process upset (loss of airflow), equipment failure (overheated bearings), or human error.

separator, a dust filter, and a storage bin between the pulverizer and burners. In either system the fly ash from the furnace / boiler is removed downstream by baghouses, electrostatic precipitators, or scrubbers. The process equipment most susceptible to explosions are the pulverizers, cyclones, dust collectors, storage bins, and conveying lines between these enclosures. (See Figure 1) Explosion venting of the pulverizer is not allowed per NFPA 8503, so the available responsive techniques are pressure containment or explosion suppression.

Although containment is designed to prevent rupturing of the pulverizer, internal components, such as the classifier, can be damaged. Explosion suppression can be applied to prevent internal damage as well as extinguish the ensuing fire. Explosion suppression utilizes pressure sensors to detect the initial pressure wave and release dry powder suppressant agent, within milliseconds, into the pulverizer. The suppression system controller interfaces with other process controls to initiate fan shutdown and other similar process changes. Conveyance Piping Deflagration propagation through interconnecting ductwork not only spreads the fire hazard, but also can cause pressure piling. This is where the pressure is built up in adjoining vessels prior to the flame arriving. The ensuing secondary deflagration in the connected vessels now starts at an increased pressure with correspondingly more serious consequences - both in terms of the rate of pressure rise and the final pressure. To prevent deflagration propagation explosion isolation is employed. This is accomplished by either: a fast acting mechanical valve system, or a chemical suppression system on the piping. Typically, mechanical isolation systems are used on piping of 24 diameter and smaller. Ductwork, and pipe diameters, greater than 24 require the dry powder chemical isolation systems. Cyclone / Dust collector / Pulverized fuel bins The cyclone, baghouses, and pulverized fuel bins can employ containment, explosion suppression, or explosion venting as the responsive strategy. Generally, due to the large sizes of these vessels, explosion venting tends to be the most economical solution. NFPA 68, 1998 edition recommends the use of
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Table 1 Comparative Auto-ignition Times and Temperatures Bituminous Coal Sub-bituminous Coal 1 Auto-ignition Time 90 to 120 days 15 to 30 days1 o o 1 Auto-ignition Table 466 C (870 F) 407oC (765oF)1 Table 2 Comparative KST and PMAX Type of Coal KST(Explosibility Constant) Sub-bituminous 209 bar-m/sec2 Bituminous 154 bar-m/sec2 Bituminous 129 bar-m/sec3 Bituminous 55 bar-m/sec4 Lignite 123 bar-m/sec4
1

PMAX (Maximum Explosion Press.) 7.2 barg2 (104 psig) 7.1 barg2 (103 psig) 9.2 barg3 (133 psig) 9.0 barg4 (131 psig) 9.1 barg4 (132 psig)

POWER ENGINEERING, August,1994, Fire protection considerations when switching fuels, by James B. Biggins. 2 Determined by ISO 6184/1 (ASTM E1226) test methods at Fike Corporation. 3 NFPA 68 Guide for Venting of Deflagrations, 1998 edition 4 Dust Explosions in the Process Industries, 1991, R.K. Eckhoff

Responsive strategies come into effect after a deflagration (explosion) has started and are designed to minimize or eliminate damage due to deflagration pressures. There are two principle systems for processing, distributing, and burning pulverized coal; direct firing systems and storage firing systems. In a direct firing system, the coal is gravity fed into the pulverizer from the coal bunker, where it is dried and pulverized, then pneumatically conveyed to the burners in a single continuous operation. A storage firing system also includes a cyclone 2

For containment, the current version of NFPA 8503 clarifies the 50 psig design requirement requires that the pulverizer components be tested to 200 psig. The air supply ducts to the pulverizer are not included in this requirement but NFPA 8503 states, consideration shall be given to the fact that this ductwork can be exposed to explosion pressures from the pulverizer. Explosion venting can be effectively utilized to prevent the rupturing of this ductwork and protect the primary air fan.

2000 Edition of API RP520 Part 1, Published

Dean Miller Rupture Disc Product Manager Committee Member API RP520 The 2000 Edition of API RP520 Part I is now available from the American Petroleum Institute. API RP520 Sizing, Selection, and Installation of Pressure Relieving Devices in Refineries presents recommended practices and is intended to supplement ASME Section VIII requirements. A significant amount of work has been done on the 2000 Edition and changes are found throughout the document. The rupture disc sections have been re-written and expanded to provide more useful information to the user, including additional information on rupture disc sizing using the KR method. The following is a summary of some of the changes and additions: All of the definitions have been consolidated into one area with several additions and updates, A new section on rupture disc selection provides guidelines for the process of selecting and specifying rupture discs, A new graphical representation of the relationship between specified burst pressure and manufacturing range is provided. A new graphical representation clarifies the relationship of various application parameters such as MAWP, marked burst pressure, rupture tolerance, and operating ratio. A section on pin-actuated devices was added. Section 3. Causes of Overpressure was removed. This information is found in API RP521. Appendix D: Determination of Fire-Relief Requirements was removed. This information is found in API RP521. New Appendix D: Sizing for Two-Phase Liquid/Vapor Relief. This appendix gives a summary of two-phase sizing methods for relief valves for the following scenarios: - Two-phase system of saturated liquid and saturated vapor enters the pressure relief valve and flashes. - Two-phase system of highly sub-cooled liquid and either non-condensable gas, condensable vapor, or both enter the pressure relief valve and does not flash. - Sub-cooled or saturated liquid enters the pressure relief valve and flashes. No condensable vapor or non-condensable gas present. Two-phase system of noncondensable gas or both condensable vapor and noncondensable gas and either sub-cooled or saturated liquid enters the pressure relief valve and flashes

New Appendix E: Capacity Evaluation of Rupture Disk and Piping System. This new appendix gives an example problem solving for the capacity of a relief system using the resistance to flow method (Rupture Disk KR). Revised Appendix A: Rupture Disk Device Specification Sheet. Revised specification sheet and expanded instructions for completing the specification sheet.

The 2000 Edition of API RP520 Part I can be obtained through the American Petroleum Institute by calling 202-682-8375 or at www.api.org/cat

Continued on page 6

Water Mist Fire Protection Systems Gain Momentum

2000 Factory Mutual Insurance Company. Condensed and reprinted with permission.
From Approved Product News, Volume 16, Number 2, 2000

Water mist fire protection systems gained acceptance just a few years ago as a replacement in many applications for halon gas which is now banned by most countries worldwide. The surprisingly effective firefighting qualities of water mist have led to its use in a rapidly growing number of challenging fire protection applications, including oil platforms, gas turbine enclosures, hotels, trains, ships and numerous manufacturing environments. Factory Mutual Research will soon issue a comprehensive new water mist system Approval standard (Class 5560).

The following is a list of current applications for which Factory Mutual Research will evaluate and approve water mist fire protection systems. combustion turbine enclosures machinery enclosures industrial oil cookers light hazard occupancies special hazard occupancies wet bench and other processing equipment Along with the current Factory Mutual Research Fire Performance Approval Requirements, the company is researching and developing tests for many new water mist applications, including: computer rooms local applications ordinary hazard occupancies flammable liquid storage areas

Water Mist Benefits

2000 Factory Mutual Insurance Company. Reprinted with permission. From Approved Product News, Volume 16, Number 2, 2000

What is all the fuss over water mist? What makes it so effective for so many different applications? How is it different from conventional sprinkler systems? The following are some of the critical benefits that water mist offers.
Replacement for halon and CO2 in many applications. The first major use of water mist protection systems was on ships as a replacement for CO2 and in response to regulatory requirements to provide sprinklers on passenger vessels. Water mist is environmentally benign and totally safe for occupied areas. Safer than CO2. There have been numerous instances of injuries and even deaths as a result of accidental CO2 discharges during routine maintenance and other situations. Water mist is not only safe, but actually improves the livability in fire areas by cooling and scrubbing the air. Cools the fire area dramatically. This allows firefighters to enter and extinguish fires. Cooling is accomplished due to the greater service area presented by the quasi-gas created by water mist systems, and the blocking of radiant heat by the many microscopic droplets. Uses less water than conventional sprinklers. This is a big benefit in many applications where run-off is a concern, such as cutoff rooms containing paint or flammable chemicals. Low water usage is critical in Europe where building owners must provide a collection area for all run-off. Works well against high heat release rate fires in enclosures when total flooding protection is used. For large fires in enclosures, the strong convection and high heat release rates are ideal for optimal water mist operation. In this application, the enclosure is flooded with water mist. The atomized droplets are drawn to the base of the fire and flash instantaneously to steam, expanding in volume by 1,700 times thereby displacing oxygen required for combustion. Works in partially ventilated areas. Unlike CO2 or halon, water mist will work in areas where a door or vent has been left open. Gas-based extinguishing systems typically require a sealed area so that a gas concentration can be achieved to put out the fire. Has some smoke-scrubbing qualities. Some smoke and toxic gases are absorbed by the atomized spray, and eventually settle with the water.

Unlike CO2 or halon, water mist will work in areas where a door or vent has been left open.
Prevents reignition. Again, because of its cooling effect and room flooding ability, water mist systems are very good at preventing reignition, even of oil bath fires or other pool fires. In Factory Mutual Research tests, attempts to reignite fires with a torch were often impossible because the water mist put the torch out.

Whats The Down Side?

Fire testing and component reliability testing are required to verify that water mist protection systems are effective for specific hazards. There is currently no general design method recognized for water mist protection systems. Doesnt do well on very small fires, such as trash can fires; however, it will contain small fires in an equilibrium state and cool the room enough to allow extinguishment by firefighters or facility personnel.

There must be some application or characteristic that keeps water mist from replacing all other fire protection systems. What are the drawbacks?
Its more expensive. While prices continue to fall with wider use, the fact remains that water mist systems tend to be somewhat more complicated and more expensive than conventional sprinkler systems. Its new and many authorities having jurisdiction (AHJs) are uncertain how to evaluate water mist systems. This situation is improving and the introduction of clear documentation, such as Factory Mutual Researchs soon-to-bereleased water mist Approval standard, will help manufacturers and insureds gain acceptance of water mist systems. Typically requires greater water pressure than conventional sprinklers. While some water mist systems have been developed to operate at relatively low water pressure, most water mist systems require compressed gas or highpressure pumps to create the atomized spray necessary for proper operation.

New, Intelligent Explosion Detector Minimizes Nuisance Activations

A long standing issue with active explosion protection systems has been the occurrence of nuisance activations. Current technology can detect explosions in the very early stages and initiate suppression and isolation systems in time to mitigate the destructive effects of an explosion. These detectors are typically set to activate as low as psig, and as high as 3 psig (dependent upon the performance capabilities of the system itself), but they cannot distinguish between an explosion or a sudden rise in process pressure. Now, with the introduction of the Fike Rate of Rise Explosion Detector, Patent No. 6,031,462, we have introduced digital intelligence to explosion detection, and minimized the opportunity for nuisance activations. Fike Rate of Rise Detector features include: 1. Digital signal processing which constantly samples and smoothes process pressure while evaluating explosion signatures. Spurious signals are filtered, reducing or eliminating nuisance activations. 2. Rate Detection - Real explosions are identified, and suppressed, by their specific pressure signature, starting at ambient or sub-ambient pressures. Normal or upset process pressure fluctuations are realized and reported. The rate detection level, or process, can be adjusted to reduce or eliminate nuisance activations. 3. Fail-Safe Detection - Detects slow-developing deflagrations
For more information concerning Fike products and services contact Fike Corporation at 816-229-3405 or at fmpsales@fike.com or visit our web site at www.fike.com/ epvent.htm.

occurring at non-optimum combustion levels. The selectable threshold detection option is set at pressure levels higher than traditional detectors and provides an additional level of safety. 4. High Pressure Alarm Advises when increasing process pressure is encroaching on the fail-safe detection set point. It also senses abnormal pressure fluctuations and warns of conditions prior to Explosion Suppression/Isolation System activation.

Continued from page 3

lightweight rupture diaphragms because hinged venting devices are less efficient. NFPA 68 also provides vent sizing equations to determine the necessary relief area. The equations are based on the enclosures being located outdoors so they can be vented to a safe area. Indoor equipment would require discharge ducts, but this is usually impractical due to the significant increase to the vented pressure, Pred, which the enclosure will be exposed to. (see Table 3)

If venting is impractical because equipment is located indoors, then explosion suppression is utilized. An advantage of explosion suppression systems, compared to venting, is the elimination of the fire hazard. Summary Companies that process pulverized coal need to be aware that a greater potential for explosion may be present when switching grades of coal. A process safety/hazard review should be conducted to

determine the effects that switching coal may have in each system. In general, low-sulfur sub-bituminous coals of the Powder River Basin are much more likely to ignite and produce a greater explosion severity, than from high-sulfur bituminous coals. The systems that safely processed bituminous coal in the past may require design changes and a higher level of explosion protection to achieve the same level of safety with sub-bituminous coal in the future.

Table 3* Vent Discharge Duct Length

0 ft 10 ft 20 ft 10 ft 20 ft 0m 3m 6m 3m 6m

Vent Relief Area (Av)

16 24.4 ft2 ft2 1.5 2.3 m2 m2

3.0 9.6 20.6 5.8 14.5

Maximum Vented Explosion Pressure (Pred)

psig psig psig psig psig 0.2 0.7 1.4 0.4 1.0 barg barg barg barg barg

*Based on an enclosure volume of 1500 ft3, L/D ratio less than 2 KST of 154 bar-m/sec, Pmax of 103 psig, and Pstat of 1.5 psig.

Fike Corporation announces the release of DisCalc 2.10 Rupture Disc Sizing Software, now complete with the Companys Pressure Relief Products Catalog on CD-ROM
BLUE SPRINGS, MISSOURI Fike Corporation has simplified the task of sizing and selecting a rupture disc for your applications, with the introduction of DisCalc Version 2.10. This software upgrade sizes rupture discs using the industrys current standard methods. The program is Windows 95/98 and NT compatible and now includes catalog information on the companys complete pressure relief product line. Software features include: User defined preferences for language (multiple language choices) and units of measure ASME Section VIII, API RP520, ISO 6718, and prEN ISO 4126-6 Sizing methods help text guide users through the various sizing methods Project database allows user to document and maintain operating conditions and rupture disc specifications for a nearly unlimited number of installations Specification sheet output to Excel format for easy editing, e-mailing, printing or saving When a rupture disc model is selected, the calculations use the minimum net flow area for that particular model and calculate the smallest size of that model that meets the area requirements Specification tool guides the user through the specification process, including manufacturing ranges, rupture tolerances, operating ratio, materials, and accessories On-the-fly help text on many fields to assist the user Comprehensive product information at your fingertips To request a free copy of DisCalc , contact your local Fike Representative, call Fike Corporation direct at (816) 2293405, e-mail fmpsales@fike.com, or checkmark the appropriate box on the reply mailer and return to Fike.

New book details latest developments in reducing accidents in the chemical industries and beyond
New York The American Institute of Chemical Engineers (AIChE) held its 34th Loss Prevention Symposium as part of its Spring National Meeting. Proceedings from that symposium, founded in 1967, continue to be the most reliable sources of practical information on reducing accidents in the chemical process and allied industries. The proceedings book from the most recent conference is now available from AIChE, presenting a variety of plant proven strategies for safer process operations and maintenance. LPS 2000 Proceedings of the 34th Annual Loss Prevention Symposium, a 500-pluspage soft cover book that covers new developments in the field of electrical equipment design for hazardous areas, including the impact of recent changes in the National Electric Code, toxic hazard recognition and exposure limits on both new and existing facilities, and a host of other safety issues. The book also explores topics in: fire protection; health and toxicology aspects of loss prevention; fire, explosion, and reactivity hazards; and overpressure protection alternatives. A section on case histories of loss prevention incidents from how a carefully conducted root cause analysis can reveal something totally unsuspected at the start of an investigation, to the need for widely distributed case histories through international accident databases emphasizes how such incidents could be prevented or mitigated in the future. Among the papers are the following: The Use of Physical Properties to Identify the Most Significant Contaminant in a Multi-Component System, Fire Protection in Telecommunication Facilities, The Development of Acute Exposure Guidance Levels for Hazardous Substances, Determining Safe Levels of Thermal Radiation Exposure on Personnel, Tools for Understanding Reactive Chemical Hazards Early in Process Development, Developments in Clean Agent System Design, Consider Bottom Venting for Emergency Relief of Energetic Liquids, Increasing LNG Plant Safety by Minimizing BLEVE, Electrical Equipment Design for Application in Hazardous Areas, The ThreeZone Classification System and the National Electrical Code, Cable and Cabling Systems in Hazardous Locations, A Tale of Two Explosions, Mitigation of Gas Explosions Using Water Deluge, NonConformance of Existing Pressure Relief Systems with Recommended Practices, Dust Deflagration Extinction, and Using Case Histories in PHA Meetings. AIChE Safety and Health Division, which sponsors the Loss Prevention Symposium, is committed to: furthering the application of chemical engineering to the broad field of safety and health; providing a forum for chemical engineers not actively engaged in safety and health, and alerting them to the importance of the field; and addressing the problems of safety and health, and the protection of property in the manufacture and use of chemicals. To order this and other AIChE books, contact the AIChExpress Call Center at 1-800-AIChemE (1800-242-4363), outside the U.S. and Canada, 212-591-8100, fax 212-5918888. Or see our web site at http:// www.aiche.org.

Fike SR-H Rupture Disc available with ASME Section VIII UD Certification and a certified flow coefficient of 1.88
Fike Corporation announces ASME Section VIII certification of their SR-H Rupture Disc, which can now be supplied with a UD Code Stamp and certified KR flow efficient 1.88. The SR-H Rupture Disc is ideal for hygenic applications, such as Food and Beverage Processing, Pharmaceutical and Bio-Tech manufacturing, and other CleanIn-Place applications. The SR-H meets the 3-A standard, is constructed of 316 stainless steel with choice of FDA Approved Viton,

silicone, Teflon, or EPDM sealing gaskets. This rupture disc clamps directly between standard TriClover, Tri-Clamp ferrules, has a 90% operating ratio, is non-fragmenting and is suitable for liquid, vapor and two-phase flow applications. The disc is offered in 1.5 through 4 standard sizes with burst pressures as low as 12 psig. A six page, full color bulletin details applications and capabilities of the disc. For a free copy, contact Fike.

NEWS OF NOTE
2000 Trade Shows
Fike will be exhibiting at the following industry trade shows. In many cases we can provide free or discounted admission passes to visit the exhibits. To request tickets to any of the following, indicate on the reply mailer which show you are interested in and the number of tickets required. You can also e-mail requests to bcopelin@fike.com. Be sure to provide your mailing address and phone number. ISA Expo, August 21 24, 2000, New Orleans, LA, Booth 1154 Permian Basin Oil Show, October 17 19, 2000, Odessa, TX, Booth J26 IPRO Expo, October 19 20, 2000, Miami, FL, Booth (To Be Determined)

Safety & Technology News

. . . is published by Fike Corporation in the interest of communication and service to those involved with process and industrial safety. We welcome your comments and suggestions. If you would like to continue receiving this newsletter, please complete and return the enclosed Subscriber Qualification Form.
Copyright 2000 by Fike Corporation. All rights reserved.

New VentCalc Explosion Vent Sizing Software from Fike Corporation

BLUE SPRINGS, MISSOURI Fike Corporation has simplified the task of sizing explosion relief vents with the release of the new VentCalc Explosion Vent Sizing Software. Factory Trained Fike Representatives can now help you size explosion relief vents, quickly and accurately, to the latest NFPA 68 standards. This software can also be useful as a design review tool. Recent changes to the NFPA 68 Standards can result in a reduction of required vent area, with existing venting systems, especially when the enclosure L/D is less than 2. For those conditions, applying replacement vents with a higher Pstat of the same area can provide longer service life to the customer. Since processes change over the years,

resizing can also identify enclosures at risk from under designed vent systems. For more information, or the name of your local Fike Distributor, checkmark the appropriate box on the reply mailer or call Fike Corporation at (816) 229-3405.

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704 South 10th Street Blue Springs, MO 64015 U.S.A. (816) 229-3405 Fax (816) 228-9277 e-mail: fmpsales@fike.com Web Site www.fike.com

DATED MATERIAL