9/22/2015

RiskLogicInc.

RiskLogicInc.

48DimmigRoad,UpperSaddleRiver,NJ07458

Phone:(201)9300700

Fax:(201)9308795

www.risklogic.com

January2003:FireProtectionforAirPreheaters
Although fires in air preheaters (ap's) of US power plants are infrequent, the result can be extensive
damage and downtime of several months. Here, we consider steps that can be taken to minimize the
incidenceandconsequencesoftheseevents.
Basically we are dealing with a heat exchanger that uses hot flue gas to heat primary and secondary
boiler combustion air to increase efficiency of fuel combustion. Although there are two basic types,
RecuperativeandRegenerative,the"rotaryplateregenerativetype"isbyfarthemostcommonlyusedin
theUSAutilityindustryandisthetypeweshallfocusonhere.
Thistypeofunithasabearingsupportedrotorshaftinahousingtowhichsegmentalbasketscontaining
the heating surface (plates) are attached. As the rotor turns, heating surfaces pass through the hot gas
streamabsorbingheatwhichisgivenuptowarmincomingcombustionair.
Ap's are subject to severe fire damage when ignition of combustible deposits in the baskets occurs.
Thesedepositsareusuallytheresultofcarryoverunburnedcarboninthefluegasesinoilorcoalfired
units. This occurs most during periods of poor firing conditions or start up, when plates are cold and
belowthedewpointoftheproductsofcombustion.Thisisacceleratedbythescalewhichformsonthe
plates in the corrosive flue gas stream and moisture laden air stream, and by the effect of alternate
heatingandcooling.Unburnedcoalcanbecometrappedinthescale,mostlyonthehotendoftheunit
wherehotfluegasenterstheheattransferelement.
Afireinvolvingoildepositswouldbecharacteristicofanyordinaryoilfire.Coaldepositscanigniteto
form a hot ember type fire. The fire is aggravated by the air velocity through the unit as well as the
excess oxygen it provides. Fire propagation is a concern due to deposits which may have adhered to
surfaces of ductwork and the precipitator unit. Undetected, an ap fire can develop temperatures
exceeding 3,000F, and become a metal fire involving the ap structure itself. Long before this,
elevated temperatures severely reduce the structural steel strength and should be considered a limiting
parameter.
Whathumanelementconsiderationscanbeusedtomitigatethefirehazard?
Operators need to be aware of (1) the possibility of creating a fire hazard with offratio firing of oil
burnersandigniters,(2)thepossibilityofoilcarryoverduringcoldstart,(3)theimportanceofregular
scheduledsootblowingpermanufacturerinstructions,(4)theneedtomonitorpressuredropacrossthe
aptodetectplugging,(5)closemonitoringthroughobservationportsinallducts,strategicallylocated
foreasyviewingofthebaskets,and(6)theimportanceofastoppedrotoralarmtothecontrolroom.
Whatelsecanbedone?
Equipment suppliers often provide air inlet and outlet monitoring thermocouples. Some can provide a
dedicated fire detection and/or suppression system. Units usually have steam or air systems for soot
blowingandhavewaterspraynozzlesforbasketwashdownwhentheboilerisdown.
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Thermocouplesarenottooreliableforfiredetectionbecauseofheatdilutionduetoairandgasflow,the
differentialneededbetweenactualoperatingtemperatureandthealarmsetpointstoavoidfalsealarms,
poorhotspotdetectioncapability,andthelargenumberneededtocoverthecrosssectionoftheairand
fluegasducts.Similarproblemsarefoundwhenusingspottypefiredetectors.Productsofcombustion
detectors are not suitable due to the dust atmospheres and high particulate environment. Continuous
wiretypedetectorswouldgivebettercrosssectioncoverage,buthavemanyofthesameweaknessesas
thermocouples.
Infrareddetectorsprovidesomeadvantages.Theyrespondtoconstantlevelsofradiation,suchaswould
be emitted by a rotor hot spot. Several, placed across the cross section of the air inlet duct only, and
directedwiththelenspointedatthebasketswouldnotbeasaffectedbytheheatofdilutionfromgasor
air flows. The differential set points between the operating and fire condition are eliminated, and in
detectinghotspots,therotorrevolutionsgivesacompletescanoftheentirerotorbasketsysteminshort
time(rotorrevolutionisaboutoneperminute).Inadditiontheyhavequickresponsetime.
This is the preferred choice. And when located in the air inlet duct, there is lower basket temperature
which minimizes background radiation, more favorable atmosphere and less airborne particulate.
However, there are some disadvantages, primarily cost each detector would require a water cooling
systemandanairsootblowingsystemtooptimizetheoperationalcapability.
Severalsuppressionalternativesareavailable.
Water spray, with open nozzles inside the ap, connected to a water supply through a deluge valve
openedbythefiredetectionsysteminstalledprovidescooling,andsteamproducedaswaterimpinges
on hot metal surfaces will have a smothering effect. There are disadvantages: (1) water collection or
drainage is needed to prevent excessive loads on ductwork, (2) open spray nozzles opposing the air
flow tend to clog without nozzle protection, and (3) possible thermal shock to rotor and housing
dependsonthemagnitudeofthefireandtheassociatedmetaltemperatures.
Gaseous systems operate best as a total flooding system with a soak time. Ap's duct dampers cannot
normally be relied on to provide a tight shutoff. With the high leak rate, gaseous flooding becomes
inappropriate.
Foamswouldreducethenecessaryquantityofwaterandhavegoodsuppressanteffectiveness,butare
notaseffectiveaswaterasacoolingmedia.
Conclusion
High velocity air and gas through ap's provide excess oxygen, rapid fire intensification, high metal
temperature and ultimate structural failure. Remedial activities to minimize the probability of a fire, as
well as reducing combustible deposits upon which fire can propagate are essential. Early detection,
quickactionbyoperatorsandeffectivemeansofextinguishmentcombinetoavoidmajordamageand
lengthydowntime.Infraredtemperaturemonitoringisconsideredthebetteroftheavailablechoicesin
thesuggestedlocation.Thiscanbesupplementedbyfixedtemperatureheatsensorsinthesealareaof
therotorbasketwheretherearenothighflowratesofairorgas.Thesedetectionsystemsshouldalarm
totheControlRoom.
Uponreceiptofalarms,operatorsmustinitiateimmediateactiontoprovidevisualconfirmationofafire
condition.Athreetofiveminuteresponseshouldbethegoal.Oncefireisconfirmed,emergencyboiler
trip procedures should be initiated to reduce air and flue gas flow rates. Water spray suppression
systems should be activated. This can be local or control room manual action, with a 5 minute auto
initiationprovidedfromthetimeoftheinitialdetectionalarm.
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Suggestedwaterspraydesignis0.3gpmpersqftovertheentirecombustionairandfluegasductcross
section from both sides. Fire hose stations for manual fire fighting should be available in the general
areaoftheap.

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