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Incident summary
On 9 Dec 2000, at about 2:30am, three personnel were
trying to re-start the boiler when an explosion occurred inside
the furnace of the boiler.
The three personnel were badly injured with more than 50%,
2nd degree burns on their bodies.
Two of them subsequently passed away later in the hospital:
Deceased 1 - Technician/ Male / 23 yrs old
Deceased 2 - Technician/ Female / 21 yrs old
6
Smoldering Fires
- (16 %)
Flammability range
Component
H2
CH4
C2H2
C2H4
C2H6
C3H6
C3H8
iC4H10
nC4H10
iC5H12
nC5H12
CO
H2S
CH3OH
LFL
4.1
5.0
1.5
2.6
3.2
2.0
2.1
1.9
1.6
1.4
1.3
12.5
4.3
6.7
Temperature
(oC)
175
465
305
560
300
420
(oF)
347
869
581
1040
572
788
Carbon
700
1292
Fuel or Chemical
Carbon - bi sulfide
Carbon monoxide
Charcoal
Coal-tar oil
Coke
Cyclohexane
Diethyl ether
Ethane
Ethylene
Ehtyl Alcohol
Fuel Oil No.1
609
580
700
245
160
515
490
365
210
300
1128
660
1076
1292
473
320
859
914
689
410
Temperature
(oC)
(oF)
n-Butane
405
761
n-Heptane
215
419
n-Hexane
225
437
n-Octane
220
428
n-Pentane
260
500
n-Pentene
298
569
900
Peat
227
440
Petroleum
400
752
800
Phosphorous, transparent
120
Production gas
750
1382
Propane
480
842
Propylene
458
856
p-Xylene
530
986
Toluene
530
849
400
752
Styrene
490
914
Wood
300
572
Xylene
463
867
10
Consideration
Oxygen : Force draught Fan and Draught Control
Explosion Hazard
Most of explosions occur when the equipment involved in a
state of change such as startup and shutdown.
The most common source of furnace explosion is come from:
Lacking knowledge of the lighting procedure
Do not aware an accumulation of flammable gas inside the
furnace per time spent,
Unsuccessful in the first attempt to ignite burner in
accordingly with the purging period and
Failure of all safety devices.
HOW TO PROTECT?
12
Training
13
14
15
16
STANDARD SCHEMES
Examples of the relevant design engineering practice and
standard drawings for design & engineering of control &
safeguarding systems.
DEP
Relevant S-Drawing
Description
32.24.20.30
32.24.20.38
32.24.20.37
32.24.20.33
32.24.20.40
S 24.036-B
32.24.20.42
(1)
S 24.035-O
(2)
17
Prior to starting the ignition burner, it shall be ensured that the fire box does
not contain a flammable mixture - either by performing a gas test or by
adequately purging the furnace .
The ignition burner shall give a stable flame, that will not be blown off/out by
the air/fuel/steam flow through the main burner. Once installed, it shall be
positioned such that ignition of the main flame is instantaneous. In case of
manually started furnaces/boilers, the size and position of the ignition flame
shall be such that it is clearly visible for the operator starting the main burner.
In case of manually started systems, the operator shall have unobstructed
access to the main burner cocks, whilst simultaneously observing the ignition
flame.
In the case of start-up on fuel oil, the volume of the line from burner cock to
atomiser has to be taken into account; the attempt for ignition starts at the
moment fuel oil enters the radiant cell. If the line between burner cock and
atomiser is to be blown empty, the ignition burner shall be working or
simultaneous gas firing shall be present.
18
For gas start-up, no start up trial should last longer than 5 seconds,
whatever the different furnace volume. If, after 5 seconds a main flame
does not start, the cause of the start failure should be established before a
next start attempt is taken. For oil start-up the maximum trial time can be
relaxed to 10 seconds.
Repeated start-up trials are accepted in case of forced- draught firing
provided the air blower remains in operation and a waiting time of one
minute is adhered to in-between start trials. For cold natural draught
furnaces intermediate gas testing of the radiant cell is essential; the second
attempt shall not less than 5 minute and longer if the furnace is cold natural
draft system.
For hot natural draught furnaces a waiting time of one minute can be
accepted.
A common convection bank/waste heat boiler can trigger an incident,
irrespective of the flammable mixture accumulation (which only relates to
conditions in the radiant cell). This strengthens the arguments for restricting
any start-up trial to a maximum of 5 seconds as well as for the intermediate
purging and/or gas testing.
19