BOILER FURNACE SAFETY

Prevention of Furnace Fire, Explosion & Flammability Limits

1.

The basic requirement for safe boiler operation is understanding explosion.

This discusses the requirements on:
a. Flammability limits of fuels and/or flammable/combustible mixtures; upper (UFL) and
lower (LFL) flammability limits as listed in the Table below.
b. Ignition temperatures of fuels and/or flammable/combustible mixtures
c. Ignition energy to initiate fire or explosion.

2.

If a fuel-air mixture is outside the limits of flammability, will ignition, combustion or

explosion is possible?
The limits of flammability of fuels or flammable/combustible mixtures are given at ambient
temperature and for homogenous fuel mixtures.
As the flammable/combustible mixture temperature is raised, the limits of flammability
widen until the minimum auto-ignition temperature of the fuel or flammable/combustible
mixture is reached.

3.

At the auto-ignition temperature, the fuel or flammable/combustible mixture may ignite in

the absence of any form of ignition sources or energy.
Normal boiler operating limits: 0.85 to 2.0 stoichiometric.
Outside the above limits, the useful heat generated by ignition of the fuel or
flammable/combustible mixture is reduced.
At the extreme fuel mixture ratios, the heat released would not maintain the fuel mixture
above the ignition temperature, not sufficient to sustain combustion, and the reaction would
stop.

4.

The pre-requisite for safe operation of the boiler is the ability to immediately and
continuously ignite the fuel or flammable/combustible mixtures within the range of
conditions given below:
a. Allowed for by the safe boiler operating instructions, and
b. The limits of the boiler controls and safety interlock system

5.

It is important to purge the boiler furnace before light-up of the first burner. This is for
safety to ensure:
a. to reduce the flammability limits of the fuel or flammable/combustible mixtures
substantially to below the limits at ambient temperature; especially for boiler light-up
immediately after boiler tripping/shut-down at high load.
b. to dilute the fuel or flammable/combustible mixture concentration in the boiler
furnace during light-up; the recommended safe limit is at or below 25% of the Lower

Explosive Limit (LEL) or Lower Flammability Limit (LFL) of the fuel or

flammable/combustible mixtures in the boiler furnace.
6.

During boiler light-up, ensure that the fuel mixture is immediately ignited as it enters the
boiler furnace during start-up; i.e. the burner fuel ignitor flame is established prior to
admitting the fuel into the boiler furnace.

7.

Burner fuel ignitors or pilot burners used should provide adequate ignition energy required;
this depends on the burner system design, operation and fuel used for the boiler.

8.

A good safety practice is to utilize increased ignition energy during start-up and during very
low load operation (below 10% to 20% depending on the type of fuel used), and during
shutdown above the normally required minimum ignition energy.

Coal Dust (Pulverized coal)

> 55

2.0 25.0