Extinguishing Coal and Coal Dust Fires

GEN-SP-4106-01

Revision: 0 Date: 01/01/2020

Submitted: /s/ Chase Smith Safety Coordinator

Reviewed: /s/ Chris Dodds Manager, Generation Safety

Reviewed: /s/ Kelly Bradley Director, Safety

Approved: /s/ Derek Bell /s/ Kevin Noblet /s/ John Bridson S Dir, Safety & Training VP, Safety & Ops Planning VP, Generation

Revision List

Rev Number Date Comments

0 01/01/2020 Issue for use.

Revision 0 01/01/2020 1 GEN-SP-4106-01: Extinguishing Coal and Coal Dust Fires

1. Purpose

1.1. This document explains the proper way to extinguish an incipient stage coal dust fire except for those occurring on a coal storage pile. This includes fires in dust collectors, silos, hoppers, bunkers and on conveyor belts. For coal storage pile fires refer to GEN-SR-6109: Fuels Handling.

2. Scope

2.1. This document applies to all Evergy employees and visitors when at any Evergy Generation facility or while performing Generation duties.

2.2. Contactors that do business with Evergy Generation shall comply with the Contractor Safety Requirements (CSR) document.

2.3. If local, state or federal laws and/or regulations pertaining to any given condition are more stringent than the Evergy rule, the more stringent law or regulation shall take precedence.

2.4. This procedure is intended to be used by personnel with the experience and training required to safely respond to the hazards of incipient stage coal dust fires.

3. References

3.1. OSHA Laws and Regulations

3.2. GEN-SR-4106: Fire Protection

3.3. NFPA 13: Standard for the Installation of Sprinkler Systems

3.4. PRB Coal Users Group Best Practices

3.5. MSHA White Paper: Past, Present, and Future Fire-Retardant/Resistant Requirements for Materials Used in Underground Coal Mines

4. Definitions

4.1. Chemical extinguishing agent – chemical additive that allows water to penetrate coal dust or creates a smothering foam blanket e.g. F500, FireAde 2000.

4.2. Coal storage container – a hopper, silo or bunker used to contain coal.

4.3. Deflagration – a fire characterized by a rapidly propagating flame front at a velocity less than the speed of sound.

4.4. DRPGM – Direct Reading Portable Gas Monitor.

4.5. Fire barrier chemical – a special chemical agent that when applied to the top of a coal bunker creates a barrier that excludes oxygen. This chemical can be provided by a service provider if not available at the station.

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4.6. Fuel Yard Personnel – Panel Operators, Fuel Equipment Operators, Assistant Fuel Equipment Operators, Reliefmen, Fuel Equipment Mechanics and all Fuel Management.

4.7. FOAMJET TFT nozzle – foaming attachment that fits on the 1 ½” hose.

4.8. Incipient stage fire – a fire which is in the initial or beginning stages that can be controlled or extinguished by portable fire extinguishers, Class II standpipe or small hose systems without the need for additional protective clothing or breathing apparatus.

4.9. PRB – Powder River Basin.

4.10. Proportioner – a device that mixes foam and water to a preset amount.

4.11. Propagate – to cause to extend to a broader area or larger number; spread.

5. Responsibility

5.1. All Evergy employees and visitors shall comply with this document when at any Generation facility or while performing Generation duties.

5.2. Generation Superintendents – are responsible to ensure all assigned personnel are trained in extinguishing an incipient stage coal dust fire.

5.3. Plant Safety Coordinators – are responsible for coordinating annual incipient stage fire extinguishing training which includes how to extinguish incipient stage coal dust fires. Sends training documentation to Safety and Training Support.

5.4. Safety and Training Support – maintains documentation of annual training.

6. Safety

6.1. A smoldering dust fire presents less of a hazard when left alone than when disturbed by improper fire extinguishing techniques.

6.2. There are contract service groups that will assist in fighting special types of fires, including deep-seated fires in coal hoppers, silos and bunkers.

6.3. When preparing to extinguish a coal dust fire, care shall be taken not to disturb the coal dust because dispersal can lead to a much larger fire or even an explosion if in a confined area.

6.3.1. When using a hose to lay down water or foam on a dust fire, do not use a direct stream of water. Use the hose nozzle on its mist or fog setting to minimize the chance of dispersing the dust and causing an explosion.

6.3.2. If there is no functioning fire hose or F500/FireAde 2000 extinguisher readily available, an ABC chemical fire extinguisher may be used. The pressure from a fire extinguisher can propagate the fire into an explosion if it is in a confined area. When using an ABC chemical fire extinguisher, bounce the stream off of a nearby flat surface to avoid disturbing the dust.

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7. Instructions

7.1. Basics – these details apply to all coal dust fires:

7.1.1. Never attempt to extinguish a dust fire by yourself.

7.1.2. Use a DRPGM to monitor for CO and other potential hazardous gases while attempting to extinguisher a fire in a confined area or indoors.

7.1.3. Before attempting to extinguish any incipient stage coal dust fire:

7.1.3.1. Report the fire to the Control Room. The Fuel Foreman shall also be informed if available.

7.1.3.2. Evacuate personnel in the area and adjacent areas.

7.1.3.3. Suspend all coal feeding operations in the area.

7.1.3.4. Map the area with a thermal imaging camera or thermal pyrometer to define where the fire is located and to determine if there are any other dust fires in the vicinity.

7.1.3.5. Gather all personnel and equipment needed to extinguish the coal dust fire in a safe area adjacent to the scene.

7.1.3.6. If possible, wet down the area surrounding the dust fire in all directions to help control the spread of the fire.

7.1.4. Once the above steps are completed the fire can be extinguished.

7.1.5. If the fire moves beyond incipient stage, implement the site Emergency Action Plan.

7.1.6. After the fire is extinguished, post a fire watch in accordance with GEN-SR-4107: Welding, Cutting and Grinding.

7.2. Dust Collector Fires (including the hopper)

7.2.1. Care shall be taken when the deluge system activates to ensure that the dust collector is draining. Structural damage due to excess weight can occur if the dust collector is allowed to fill up with water.

7.2.2. Burning dust can float on top of the deluge water. Use extra caution when water is draining from the dust collector to ensure that the fire does not spread along with the draining water.

7.2.3. Never open a door or other access to the inside of a dust collector that is on fire or may be on fire to prevent creating a draft that disperses coal dust and causes an explosion.

7.2.4. Indications or symptoms of a dust collector fire could include:

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7.2.4.1. Abnormally high CO level

7.2.4.2. Smoke from discharge stack

7.2.4.3. Warm spots on hopper

7.2.4.4. Paint discoloration

7.2.4.5. High temperature alarm

7.2.4.6. Deluge system trip

7.2.4.7. Burning coal smell

7.2.5. Actions in the event of a fire

7.2.5.1. Notify the Control Room that there is a fire and report the location. The Fuel Foreman should also be informed if available.

7.2.5.2. Stop airflow and equipment.

7.2.5.3. Trip any equipped deluge system if it does not trip automatically.

7.2.5.4. Activate the manual fire suppression system if equipped.

7.2.5.5. Check hopper and outside of the dust collector with a laser pyrometer or infrared camera to ensure the areas are cool.

7.2.5.6. Smell for burning coal.

7.2.5.7. Drain water and dust from bin.

7.2.5.8. At this point, the fire should be extinguished. Open an access door slowly and carefully and smell for smoke. Be sure to stay away from the front of the door when opening it.

7.2.5.9. Open all doors; wash down the top of the tube sheet and hopper with a high- pressure hose using an open mist spray.

7.3. Hopper (excluding dust collector hoppers), Silo and Bunker Fires

7.3.1. Actions in the event of a fire

7.3.1.1. Notify the Control Room that there is a fire and report the location. The Fuel Foreman should also be informed if available.

7.3.1.2. When an indication of burning coal is detected in a hopper, bunker or silo it should be investigated immediately. If a fire exists, a plan shall be developed to fight it.

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7.3.1.3. Stop all feeding and emptying of the affected bunker or silo in order to analyze the temperature map and develop an action plan. Be sure all sources that could introduce fines to the enclosure have been deactivated. This includes bag house returns, pneumatic conveying systems, screw conveyors, cyclone separators, airlock feeders, dribble chutes and belt scrapers.

7.3.1.4. If possible use a thermal imaging camera, laser thermometer or other thermal detection device so the area can be mapped to show the fire location and intensity inside the enclosure.

7.3.1.5. The immediate area above the bunker or silo should be washed down prior to attacking the fire to prevent a possible coal dust explosion. Firefighting efforts could cause the burning area to collapse on itself creating a blowback through the top of the bunker or silo. This could ignite dust that has settled on beams and other items in the tripper or cascade room.

7.3.1.6. Do not use a fire hose with a straight stream of water to try and drill through the top layer of coal to get to the seat of the fire. This technique can stir up coal dust resulting in a flash explosion inside the container. A secondary explosion can also occur outside the enclosure as the heat ignites airborne dust.

7.3.1.7. Do not attempt to smother the fire with a layer of fresh coal.

7.3.1.8. Bunker and silo fires shall be extinguished using permanently installed fire extinguishing systems, manual fire extinguishing tools or a combination of both.

7.3.1.8.1. A fixed (permanent) system is installed inside a coal storage container that is designed specifically for that type of enclosure. These systems can be used for dust control and housekeeping and may have the ability to deliver a chemical extinguishing agent (F500/FireAde 2000) into the fire. The downside to using the fixed system is that the entire enclosure may need to be flooded with agent to reach the fire’s hot spot.

7.3.1.8.2. Manual fire extinguishing tools include foam carts, water hoses and foam proportioners. Experience has shown that the best method of extinguishing a fire is to get the agent directly to its seat. To do this, the location of the fire within the enclosure must be known, there must be access to the enclosure and the proper tools to deliver the agent must be available. The primary tool used to deliver the agent directly to a hot spot is the foam proportioner. It can be directed over the hot spot inside a coal storage container, letting the agent soak down into the coal, extinguishing the fire. Properly-trained personnel may also use a piercing nozzle.

7.3.1.8.2.1. When using foam in an empty bunker or silo, care must be taken that the foam is not allowed to drop into the bunker/silo as this may cause a dust cloud to be dispersed within the empty bunker/silo increasing the likelihood of a combustible dust explosion.

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7.3.1.8.2.2. When using foam, aim the foam at a vertical surface or wall and let the foam fill the area over to the hot spot inside a coal storage container. Let the foam/agent soak down into the coal, extinguishing the fire.

7.3.1.8.3. If it is impossible to get the agent directly to the seat of the fire, the storage container may be manually flooded using a fire hose set on fog/mist or an extinguishing agent using the foam proportioner through the top of a coal storage container.

7.3.1.8.3.1. By using the medium expansion foam eductor, the nozzle can be positioned over the enclosure opening and plant personnel can operate the foam proportioner from a safe distance.

7.3.1.9. If the fire is deep-seated it may be necessary to call in additional resources to help in extinguishing the fire (e.g. M&M Fire Protection).

7.4. Conveyor Fires

7.4.1. Conveyor fires can generate toxic fumes from burning belting, electrical wires or rubber rollers.

7.4.2. No personnel (unless fire brigade qualified) shall enter a conveyor structure or tunnel if the conveyor is on fire to avoid breathing toxic fumes.

7.4.3. When extinguishing a conveyor fire, consideration shall be made regarding its location. Conveyors can either be open and outside, inside an enclosure or structure, or it can be underground.

7.4.4. Actions in the event of a fire

7.4.4.1. Notify the Control Room that there is a fire and report the location. The Fuel Foreman should also be informed if available.

7.4.4.2. If the conveyor deluge system fails to operate automatically, initiate it manually.

7.4.4.3. An outside conveyor fire is a Class B fire and shall be extinguished in accordance with GEN-SR-4106: Fire Protection.

7.4.4.4. To extinguish a fire on a conveyor inside a structure:

7.4.4.4.1. If the fire is still in the incipient stage and the conveyor belt is not on fire, extinguish it like any other coal dust fire.

7.4.4.4.2. If the fire is beyond the incipient stage or the conveyor belt is on fire:

7.4.4.4.2.1. The enclosure shall not be entered by plant personnel (unless fire brigade qualified).

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7.4.4.4.2.2. If the deluge system has initiated, allow it to continue to operate until the fire department arrives.

7.4.4.5. Fires on underground conveyors

7.4.4.5.1. The underground area shall not be entered by plant personnel (unless fire brigade qualified).

7.4.4.5.2. The deluge system shall be tripped and the fire department called.

8. Documentation and Recordkeeping

8.1. Generation Safety will maintain this procedure. The original will be stored electronically by Generation Safety and a copy will be available for use on the Safety website. A signed hard copy will be maintained by Generation Safety. There will be no other hard copies produced or maintained. This procedure shall be reviewed periodically by Generation Safety in accordance with department policy. Superseded revisions shall be archived in accordance with corporate policy.

8.2. To request a revision to this procedure, see your supervisor or Safety Coordinator.

9. Attachments

9.1. None.

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