CHEMETRON LOW PRESSURE CO2 SYSTEM DESCRIPTION

F.L. SMIDTH INC

Carbon Dioxide System liquid System for Active Fire Control
Protection of the Dust Collectors
Upon an indication of elevated temperature in the Dust Collector, indicating a fire, CO 2
can be discharged into the Dust Collector. The system is designed to flood the Dust
Collector to 75% CO2 by volume.
This is achieved by discharging liquid CO 2 through appropriately sized pipe and nozzles.
The liquid CO2 at atmospheric pressure will "flash" into vapor and particles of solid CO 2
which will quickly sublime to vapor. This CO 2 vapor will be mixed with the Dust Collector
internal gas volume in free efflux flooding to reach the 75% concentration, 30% obtained
in the first 2 minutes.
Emergency
In case of sudden rise in dust collector temperature or any smoke indication in the coal
system, the system must be attended immediately.
SEQUENCE OF CO2 SYSTEM OPERATION
1.

The dust collector temperature will be continuously monitored.

2.

If there is a sudden rise in temperature, will initiate a CO 2 discharge. This will

necessitate the closing of a contact wired to Zone 1 (Terminals +7 -8) of the mill CO 2
Control Panel.

3.

In the event that a CO 2 discharge is needed and is not initiated from the heat
detection it can be initiated from a local pushbutton at the dust collector. Indicating
light indicates availability of power for actuation. This PB is wired to terminals
"Manual Discharge" (Terminals +9 -10) of the dust collector CO 2 control panel. The
discharge will be immediate upon actuation.

4.

Actuation by any means will sound alarms in the vicinity of the dust collector and
associated equipment. Alarms will be a yeow sound.
Alarms are electrically supervised. Trouble is Fault Code F-18 on the CO 2 Control
Panel, while a wiring short is Fault Code F-39. Alarm operation code on CO 2 control
panel is Code A-04.

5.

The CO2 control panel initiates a signal to the electro-manual from Terminals (+23 24) of the CO2 control panel to initiate the CO 2 discharge and to stop the flow of CO 2
after the set discharge time period.

CONTROL PANEL OPERATION:

Stand-By Condition:
The control panel in the stand-by mode with commercial power and battery connected will
illuminate "SAFE" on the display.
Green LED (AC power on) will be illuminated. All other LEDs (trouble and alarm) are off.
General Trouble Condition:
Interruption of any of the electrically supervised circuits will illuminate the General Trouble
LED. The local buzzer will start sounding and the General Trouble Relay Contacts will
transfer. At the same time on the alpha-numeric display, the word "SAFE" will be
replaced with a code number.
Match the code on the display with the alarm/fault code chart to pinpoint the trouble area.
The local buzzer can be silenced by depressing the trouble silence keypad switch. At the
same time the General Trouble LED will start flashing Panel shall remain in the trouble
state until the trouble condition has been cleared and the panel reset.
A maximum of six trouble conditions can be displayed on the readout, one at a time on a
priority basis. In case of a Ground Fault or a Battery Trouble Condition, individual fault
light LEDs will illuminate in addition to the general trouble condition.
Manual Discharge Actuation:
If the CO2 System is actuated, the following will take place.
1.

Red "Alarm" LED will illuminate.

2.

Alarms #1 and #2 and the local buzzer will be activated.

3.

General Trouble Relay, Alarm Relay, Equipment Shutdown relays (Aux.

Outputs #1 and #2) shall be activated.

4.

The SEMPC solenoid valve will activate as programmed.

5.

The Alpha-Numeric Display shall start countdown of discharge time.

6.

At the end of discharge cycle the solenoid valves will de-energize, ending
the release of CO2. The display will indicate "rCHg".

7.

In the event of a catastrophic failure of the electrical control system, the system can
be operated mechanically utilizing CO2 pressure. (Description of Operation Mechanical as follows:)
Description of Operation - Mechanical

General:
All active fire control will be provided from a UL listed/FM approved low pressure CO 2
storage unit with 2 ton capacity. This unit has the capability to provide "multiple shot"
protection.
The discharge of a carbon dioxide system requires the operation of one pressure
operated valve situated in the system discharge piping. This valve is operated by carbon
dioxide vapor pressure from the storage unit. The titles given these valves describe their
functional position in the system. A master valve is under constant storage unit pressure
and is used to serve one or more selector valves. A selector valve is not normally under
pressure. Its function is to receive the discharge from a master valve and direct it to a
specific hazard area. A master selector valve is a selector valve at the storage unit
which is under constant pressure. This system has a master selector valve.
Carbon dioxide vapor pressure for piloting the valves at the storage unit is supplied from
the storage unit vapor space through a " pilot line to the valve control devices. A "
manual shutoff valve, which is normally locked in the open position, is included in this line
for servicing. This valve is equipped with a supervisory switch that monitors the valve
position (open or closed). An orifice union (Plate H-51G) with a 0.144" diameter orifice is
located downstream of the " shutoff valve. Its purpose is to restrict flow through the "
pilot line in the event of pilot line damage and thus minimize the rate of vapor loss. The
reduced flow also results in a more rapid pressure drop in the downstream pilot piping,
thereby providing for more sensitive supervision by an end-of-line supervisory pressure
switch.
The " pilot line pressure is supervised by an end-of-line pressure switch located in the
most remote section of pilot piping. This switch senses an abnormal drop in pressure. It
is wired into the CO2 System control panel Aux 2 (+1 2-) for that protected hazard to
indicate a trouble condition. (See Plate H-59G)
The pressure operated valve is equipped with a Supervisory Electro-Manual Pilot Cabinet
(SEMPC), an Emergency Manual Release (EMR) and a supervisory pressure switch.
The SEMPC and EMR cabinets have a pressure operated 3-way pilot valve. This valve is
equipped with a cam operator which is connected to an external operating lever, secured

with a pullpin and seal wire. This feature permits direct manual operation of the 3-way
pilot valve and, thus, the opening of discharge valve.
Description of Operation - Dust Collector Protection
(See Plates H-37N, H-47P, and H-47S)
Pilot vapor pressure is constantly supplied from the " pilot line through a check valve
and SEMPC cabinet connection "C-S" to a pilot manifold in the SEMPC cabinet. A
second source of pressure is from the storage unit discharge header. It is constantly
supplied through an armored flexible connector (Plate H-31A), through a check valve, and
cabinet connection "C-V" to the pilot manifold. If the basic source of pilot pressure is
interrupted due to a damaged pilot line, the alternate source provides the pressure
necessary for both electrical and manual means of system operation. The check valves
at both connections "C-S" and "C-V" prevent pressure loss in the event either of the
two supply paths is damaged.
Pilot pressure from the internal manifold is applied to port "C" of the normally closed 3way pilot valve and to the inlet port of the normally closed solenoid valve. Pressure from
the manifold is also supplied through cabinet port "C" to port "C" of an Emergency Manual
Release (EMR), where it provides pilot pressure to the normally closed 3-way pilot valve.
A pressure relief valve (set to relieve pressure at 450 psi) is included in this line to protect
it and the SEMPC internal manifold against over pressurization in the event it receives
liquid CO2 from the alternate pilot pressure connection "C-V." In such a situation,
increased pressure due to evaporation of the liquid will be trapped because of the check
valve at both SEMPC connections "C-S" and "C-V." The relief valve will close when
the pressure is reduced.
EMR connection "E" is connected to port "B" of the SEMPC, where it is extended
internally through open ports "B" and "E" of the 3-way pilot valve to the space above the
discharge valve piston.
The EMR is conveniently located to the hazard and can be used to operate the discharge
valve due to a failure in the normal system operation.
Operation - Electrical Actuation
A.

Electrical actuation may be accomplished by one of several means:

1. Automatic by actuation from the customer supplied heat detection.
2. Manual by operation of a local electric discharge station (PushButton).

B.

Regardless of the means of electrical actuation, the sequence is essentially the

same:

1.

The CO2 System control panel receives the signal and initiates timing, alarm, and
shutdown functions.

2.

Following that, the solenoid valve inside the SEMPC is energized to apply pilot
pressure through port "A" of the 3-way pilot valve. This causes the 3-way pilot
valve piston to move to seal off its port "B" and opens the passage between it's
ports "C" and "E." This permits pilot pressure to be applied through port "E" to the
piston of the discharge valve causing that valve to open to discharge CO 2 to the
protected space.

3.

After the established discharge time has been satisfied, the control panel deenergizes the SEMPC solenoid valve causing pilot pressure from 3-way pilot valve
port "A" to be vented. This allows pressure below the piston, in combination with
spring force, to cause the piston to return to its standby position. In so doing, valve
port "B" is opened to permit pressure above the discharge valve piston to be
vented through valve ports "E" and "B" and through cabinet port "B" to the EMR,
where it is vented to atmosphere. With pressure removed from above its piston,
the discharge valve closes to end the CO 2 discharge.Operation - ManualPneumatic Actuation

A.

There are two means of actuating the system manually without electrical
involvement:
1. Operation of the EMR.
2. Operation of the manual lever of the SEMPC.
WARNING
The hazard must be evacuated before operating the Supervisory ElectroManual Pilot Cabinet. Discharge of CO2 will be immediate.

Sequence of operation of the Emergency Manual Release (EMR) Station.

1.

Manual operation of the EMR is used only in an emergency situation such as

failure of the normal actuation means to produce the desired CO 2 discharge.
Instructional nameplates and operating instructions are provided to explain proper
operating procedures.

2.

Operation of the EMR involves removal of the pullpin and rotation of the lever to
the open position. This action forces the internal 3-way valve piston to change
position to seal off its vent port "B" and opens the passage between its ports "C"
and "E." This applies pilot pressure through interconnecting pilot piping to
connection "B" of the SEMPC and then through the open path between ports "B"
and "E" of the 3-way pilot valve to the space above the discharge valve piston,
causing that valve to open to provide the necessary discharge.

WARNING
WARNING
The hazard
be must
evacuated
before operating
the Emergency
Manual ElectroThemust
hazard
be evacuated
before operating
the Supervisory
Release, which,
in
turn,
operates
the
Supervisory
Electro-Manual
Manual Pilot Cabinet. Discharge of CO2 will be immediate.
Pilot Cabinet. Discharge of CO2 will be immediate.
3.

The discharge will continue until the lever of the EMR is returned to the closed
position.
Shutdown of equipment is initiated by the discharge pressure to a pressure
operated switch.

4.

When the lever of the EMR is returned to the closed position, pilot pressure from
above the discharge valve piston is vented in reverse of the actuation path and
ultimately to the atmosphere through port "B" of the EMR, thereby causing the
discharge valve to close, ending the discharge.

C.

Manual operation of the supervisory electro-manual pilot cabinet:

1.

Manual operation of the SEMPC is accomplished by removal of the pullpin and

rotation of the lever on the front of the SEMPC. This action rotates a cam which, in
turn, forces the 3-way pilot valve to open to apply pilot pressure to the discharge
valve piston, causing the valve to open to discharge CO 2.

2.

Shutdown of equipment is initiated by the discharge pressure applied to a pressure

operated switch.

3.

The discharge will continue until the lever is returned to the closed position and
pressure is vented from above the discharge valve in the same manner as
described for the EMR.

Carbon Dioxide System Vapor Inerting System (Inerting) For Control of Smoldering
Fires

Description of System
The function of the vapor system is to provide inert gas to prevent the creation of an
explosive atmosphere of gas or dust in the void space above the coal in the pulverized
coal bins, and to provide a fire extinguishant which is capable of being forced through any
coal accumulation so as to reach any deep seated fire created by spontaneous ignition.
The coal is fed to the coal mill where it is ground and then is picked up by a hot air stream
and conveyed through a duct system to the pulverized coal bins.
The pulverized coal is conveyed to and stored in pulverized coal bins.
Protection of Coal Stored Coal Bins
Coal is subject to spontaneous heating when confined. Carbon dioxide vapor can be
used to extinguish smoldering fires that can develop in this coal.
The CO2 vapor is gently introduced into the coal and forced by a continuous flow through
the coal in a radial flow out from the points of application. The type and number of
application points is determined by the size of the coal mass or bin. As additional CO 2 is
introduced, it pushes the CO 2 vapor ahead of it between the voids of the coal pieces until
it reaches the fire. The coal adsorbs significant CO 2. Amounts of CO2 and flow rates are
designed accordingly.
When the CO2 vapor reaches the hot spot, it reduces the oxygen, which is supporting the
burning, to near zero. The generation of new heat from combustion is then reduced,
while heat is lost by conduction to surrounding materials, resulting in cooling of the hot
spot and fire control.
The controls used for the CO2 vapor application has the capability to increase or decrease
the flow rate to ensure fire control with a reasonable amount of CO 2.
With coal stored in a confined space such as the pulverized coal bin, there exists a
possibility of an explosion or fire involving gas/dust in the space above the coal. Explo sion vents protect the bin from explosive pressure build-up. When a fire starts in the
stored coal from spontaneous ignition, the presence of a potential ignition source increases the possibility of explosion.

Carbon Dioxide Vapor (Inerting) system for the Coal Bins

The vapor delivery to the pulverized fuel bin via Pfister aeration control scheme will be
provided with a step-down pressure regulator and strainer only. The regulator will be set
(at time of commissioning) and remain set as to protect Pfister control scheme based on

pressure limit specified by Pfister. Flow rates shall be ultimately controlled by Pfister
aeration control scheme and determined by characteristic flow data of specific Pfister
equipment.
The start of the inerting system is accomplished automatically via electric pushbutton or
dry-contact input from plant control system. The Fire Control Panel (by Chemetron) will
automatically time the discharge by energizing the 3-way solenoid associated with the
specific hazard and actuating the specific pressure operated discharge valve. (Note:
Customer must be responsible for CO2 distribution via regulated Pfister connection).
Initiation of the inerting system can also be accomplished manually via lever operated bypass valve in the event of AC power loss and Battery backup of Fire Control Panel and
should be operated in this manner only in emergency conditions.

Sequence of Operation
1.

When CO2 vapor is required a signal is sent to start the vaporizer. The isolation
valve at the CO2 storage unit is normally open. This allows flow of CO 2 liquid from
the storage unit to the electric vaporizer. (The discharge gas temperature control
will be set at the time of system commissioning and test).

2.

A signal is also sent to the two solenoid operated selector valves for the bin. One
for upper discharge solenoid and one for lower discharge solenoid.

3.

A pressure operated switch is provided to annunciate the CO 2 discharge.

4.

In the event of catastrophic failure of the electrical control system, the system can
be operated using manually operated by-pass valves.

5.

The CO2 vapor discharge lines to the bin have a flow control scheme allowing the
CO2 vapor flow through that line to be increased or decreased. Unless
circumstances dictate, the initial setting of the flow control should not be changed.
(The flow control settings will be established at the time of system commissioning
and test).

Sequence of Operation of CO2 Storage Unit

1.

The CO2 storage unit stores CO2 liquid under refrigeration and is designed to
operate between 305 psi and 295 psi. The vapor pressure in the unit is shown on
the unit's pressure gauge and is monitored by a pressure switch set to actuate at
the higher level. This is to establish and maintain a nominal temperature of 0 F/-18
C.

2.

The unit includes a pressure vessel which is insulated with the insulation covered
by a painted protective metal housing. As heat penetrates the insulation, the
pressure in the vessel rises.

3.

The unit is refrigerated with coils running in the vapor space of the CO 2 stored.
When the pressure rises to 305 psi the pressure switch contact closes, starting the
refrigerator, cooling the coils in the vessel.

4.

CO2 vapor in contact with the cold coils in the vessel is cooled and condensed to
liquid, thereby dropping the pressure in the CO 2 vapor space.

5.

When this pressure drops to 295 psi the pressure switch contact opens, thus,
stopping the refrigerator. It is in stand by until the pressure rises to 305 psi again
and then the cycle is repeated.

6.

In the event of malfunction and CO 2 vapor pressure reaches either 325 psi or 275 psi,
a "Hi-Lo" pressure switch actuates a local alarm horn. The local alarm horn can be
silenced at the storage unit.

NOTE: The CO2 system is designed to function within this entire range of pressure
275/325 psi

NOTE: The CO 2 syste m is designed to

function within this entire range of
pressure 275/325 psi

7.

When CO2 is used from the storage unit and the liquid level drops, the liquid level
gauge is equipped so that at a low level of liquid, two contacts are closed, warning
that the unit needs refilling.

8. If a malfunction of the refrigeration system is not cleared before the CO 2 vapor

pressure in the unit reaches 341 psi a bleeder valve will open bleeding off CO2 vapor
to the outside. This venting of pressure causes CO 2 liquid in the unit to vaporize to
make up for the vapor bled off. This "self refrigerating" action keeps the pressure
from rising above the 341 psi level.
9. The vessel is designed to a 357 psi operating pressure. In the very unlikely event
this pressure is ever reached the unit's safety relief valve will vent off the CO 2
remaining in storage.
10. After use, the unit must be refilled.

Sequence of Operation Vaporizers

Electric Vaporizer
1. After the vaporizer has been installed and hooked up, the temperature controllers
are set. Low temperature shutoff is at 5 F. Heater control is at 70 F.
2. When CO2 vapor is needed, a signal (from customer controls) turns on the vaporizer.
The master valve solenoid must also be enenergized to allow CO 2 to flow to the
vaporizer.
3.

The CO2 flow rate is set by test during system commissioning.

4.

The discharge gas temperature can be adjusted by the heater controls.

5. A manual by pass valve at the master valve allows starting CO2 flow in the event of
master valve failure.