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Auxiliary Boiler Back Fire on Ships – Case Study

Auxiliary Boiler Back Fire on Ships – Case Study

Boiler Back Fire Incident on Ships

Outline:

Vessel was at anchorage awaiting berthing instructions.

  • 18:00hrs – Fire in engine room reported to the bridge.
  • 18:01hrs – Alarm sounded and announcement made on vessel PA system.
  • 18:03hrs – All mustered at fire station and all are accounted for, several explosion’s were being heard coming from the engine room.
  • 18:04hrs – Emergency stop for engine room operated, Quick closing valves operated & commenced boundary cooling.
  • 18:05hrs ~ 1820hrs – Fire fighting team unable to enter engine room due to heavy smoke and continuous sound explosion.
  • 18:30hrs – Explosion sound stopped, fire fighting team enter the engine room and fire extinguished using portable dry chemical extinguisher.
  • 18:45hrs – Fire extinguished and confirmed no chance of re-ignition.
  • 18:50hrs – Started cleaning the effected area and surrounding and assessing damage.

Damage:

  • Burner head assembly damaged due to boiler back fire
  • Air damper, fuel oil solenoid damaged
  • Ignition transformer and cables damaged
  • Flame eye detector and cables damaged.
  • Oil heater element, pressure gauge and thermometer damaged
  • Air blower motor.
  • Engine room fittings surrounding boiler front discolored.

Root Cause:

  • There have flashback incidents on board ships fitted with composite boiler in the past.
  • The manufacturers have issued a safety bulletin for this type of boiler which was not known to the office or Ship Staff.
  • As per the manufacturer’s recommendation, the burner can be changed to avoid a boiler back fire but this was not know to either the office/ship staff.

Contributory Cause:

  • The un-burnt fuel accumulated in the hot furnace lead to generation of a rich combustible mixture of air and fuel which was not completely purged during the pre-purge cycle prior to next start sequence. This caused boiler back fire in the furnace during re-igniting of the burner.
  • Although the exact cause of accumulation of un-burnt fuel in furnace has not been determined it is suspected that leaky fuel oil solenoid valve which lead to dripping of fuel oil in furnace after auto cut-off of boiler.
  • The boiler fuel oil solenoid valve had been opened up a number of times in the past as it was found leaking and was being overhauled by lapping the v/v disc and seat as no spare was available. The vessel did not inform the office on the condition of the valve.

Preventive action:

  • Safety bulletin issued for that type burner is included in the report.
  • For vessels fitted with the this type burner the Safety bulletin should be posted in the ECR and should be part of the engine room familiarization.
  • The makers have recommended modification to the burner which will be done on this burner.
  • Ch-Engineers of these vessels should include in their hand over notes the problem associated with this type of burner and refer to the safety bulletin.
  • Check through “peep hole” if ignition electrodes are giving spark for pilot burner and pilot burner is igniting and giving stable flame.
  • Check the funnel smoke which must be “dull black”. Black or white smoke indicates improper combustion of fuel with un-burnt fuel accumulating in the furnace.
  • Prior inspection of boiler burner or attempting to re-ignite the boiler burner after a flame failure alarm:
  • Change boiler control to manual, run the purge cycle for at least 5 minutes ensuring the blower damper is fully “open” position to ensure combustible gases purged out of furnace.
  • Check through peep hole for any hot spots near the burner area or furnace floor during purging.
  • Check funnel, must be clear of any smoke.
  • After above operation satisfactorily done, the maintenance on boiler can be carried out. Maker’s maintenance procedures during overhauling / repairing are to be adhered to at all times.

Lesson Learnt:

  • Duty engineer to check the burner flame (through peep hole) and the funnel smoke regularly during watch keeping and ensure proper combustion of fuel in furnace.
  • Regular maintenance of boiler fuel oil system components to be carried out as per maker’s instructions and at a specified interval or earlier if required.
  • Fuel oil system solenoid valves to be checked at regular intervals for positive shut off and must to be replaced if found leaking.
  • Do not attempt try to re-ignite the boiler burner without eliminating the cause of ignition failure.
    HP P