POWER DIVISION THERMAX LIMITED

PROJECT DOCUMENT TITLE REV. TOTAL SHEET

1 X 6.4 MW WHR PP, OPERATION AND CONTROL PHILOSOPHY C

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KURNOOL (FLUE GAS DAMPER OPERATION)

Typical Damper operation write-up for 1 X 6.4 MW WHR PP, KURNOOL

This power plant has two boilers operating on the waste heat from the cement kilns:-

1. One no PH Boilers generating steam with the exit gases from the Pre heater kiln
2. One AQC Boilers generating steam with exit gases from grate cooler kiln

The operation write up is intended to cover the operation philosophy for the inlet, outlet
and bypass motorized dampers for safe and efficient operation of the boilers. The
complete logic for the damper operation of these dampers will be implemented in
customer DCS system.

The write up here will deal with one PH boiler and one AQC boiler damper logic.

Types of dampers for AQC and PH boilers –

PH Bypass Damper( 11-XV-162) Motorized multilouver regulating dampers

PH I/L Damper( 11-XV-160) Motorized multilouver On/Off dampers
PH O/L Damper( 11-XV-161) Motorized multilouver On/Off dampers
AQC Bypass Damper( 12-XV-165) Motorized multilouver regulating dampers
AQC I/L Damper( 12-XV-160) Motorized multilouver On/Off dampers
AQC O/L Damper( 12-XV-161) Motorized multilouver On/Off dampers

PH Boiler-1 Damper Operation.

There are three motorized ON/OFF dampers which will act as a group.
All these dampers will also have manual operation facility from the customer DCS system

For group operation, dampers 11-XV-162(Boiler bypass damper) / 11-XV-160 (Boiler inlet
damper) / 11-XV-161 (Boiler outlet damper) will act as a group and open/close
sequentially in case of boiler trip. When boiler is brought into service mode, the dampers
are brought into service one by one ensuring the permissive.
The gas Inlet, Outlet and Bypass dampers 11-XV-160, 11-XV-161 and 11-XV-162
respectively are to be controlled from customer DCS system manually. This damper shall
also have end position limit switches like the OPEN/CLOSE. The CLOSE limit switch shall
be field adjusted such that damper cannot be fully closed. Customer DCS operator will
manually open11-XV-162 ( Bypass damper-inching type ) partially from DCS to maintain
the exit temperature, whenever higher exit temperatures are required based on
cement process requirements.

Boiler trip logic is implemented in TL control system and the CAUSES for Boiler trip are as
follows:-
i) Recirculation pump trip
ii) LP drum low low
iii) LP drum level high high
iv) HP drum low low
v) HP drum low high high

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POWER DIVISION THERMAX LIMITED
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1 X 6.4 MW WHR PP, OPERATION AND CONTROL PHILOSOPHY C

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KURNOOL (FLUE GAS DAMPER OPERATION)

In case Boiler trip is initiated in TL Control system, following EFFECTS will be initiated:-
i) One Digital output from TL control system to customer DCS system (11-
PHTRIP-001=Incase BLR trip condition, becomes 1 to 0) to initiate group
bypass for the dampers 11-XV-162, 11-XV-160, 11-XV-161.

Bypass sequence for damper operation (To be implemented in Customer DCS)

The bypass sequence of dampers can be initiated manually from Customer DCS by
operator or when boiler has tripped (if 11-PHTRIP-001=becomes 1 to 0). The completion
of the sequence will ensure that the hot gases are bypassed to pre heater fan suction
bypassing the boiler.

The sequence when started will follow the following steps.

Step-1
Permissive – 11-PHTRIP-001=becomes 1 to 0.
Action: Force Open damper 11-XV-162 (bypass damper) - Open command until getting
OPEN F/B.
Wait time: 40-60 sec (To be adjusted at site)

Step-2
Permissive – 11-XV-162 (Bypass damper) open sensed by open limit switch
Action: - Close damper 11-XV-161 (Outlet damper)
Wait time- 40-60 sec (To be adjusted at site)

Step-3
Permissive: Damper 11-XV-161 (Outlet damper) is closed sensed by closed switch
Action: Close damper11-XV-160 (Inlet damper)
Wait time – 40-60 sec (to be set at site)

Step-4
Permissive: Bypass sequence complete. (One no Digital Output to be generated from
Customer DCS to TL control system), Digital O/P Tag: 11-BYP-002, (Where complete=1)

Action: Initiate RAV trip/stop sequence after T3 (30 min) time delay. RAV trip/stop
sequence logic is to be implemented in TL control system along with drag chain conveyor
logic. Trip sequence is as follows.

11-M-711/712/713/714/715 11-M-716 (with 5 min delay) 11-M-717 (with 5 min

delay) 11-M-718 (with 5 min delay).

Boiler Starting – Damper operation sequence -

During bringing the boiler in operational mode, we recommend that the dampers be
manually opened /closed one by one instead of running on auto-sequence.
Common Permissive for Damper Opening operation are :( Common permissive
logic shall be implemented in TL Control system)
a. Boiler is ready for Damper opening Operation.
If 11-PHRDY-001 shall become o to 1 when

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1 X 6.4 MW WHR PP, OPERATION AND CONTROL PHILOSOPHY C

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KURNOOL (FLUE GAS DAMPER OPERATION)

Bucket elevator (Customer scope) is running (11-ONBCKT-001, one number

Digital out Put from Customer DCS system to TL Control system).

Drag chain conveyor (11-M-716/11-M-7717/11-M-718) 1, 2, 3 is running.

All RAV’s (11-M-711/712/713/714/715) Care running PH Boiler.

Boiler has no trip condition includes recirculation pumps running & HP/LP Drum
level is healthy etc.

One number digital output shall be generated from TL control system to

customer DCS system as “Common permissive for damper opening
Operation” (11-PHRDY-001, Ready=1)

After getting common permissive for damper opening following sequence

shall be executed in customer DCS system.

Step-1
Permissive: 11-XV-162 (Bypass damper) open (sensed by open limit switch)
Action: Open 11-XV-160 (Inlet damper) .

Step-2
Permissive: 11-XV-160 (Inlet damper) is open (sensed by open limit switch) & Boiler RDY
(11-PHRDY-001).
Action: Open D3 (Outlet damper)
Wait till 11-XV-161 (Outlet damper) open feedback received.
Step-3
Permissive: 11-XV-160 and 11-XV-161 open
Action: Close 11-XV-162 (Bypass damper gradually from Customer DCS till minimum
position is reached sensed by limit switch.

BOILER ON signal is generated.

Note: The closed limit switch shall be set at around 10% opening such that it cannot close
fully. This is to ensure that there is no build-up of dust on the damper 11-XV-162.

RAV starting (To be implemented in TL Control system).

There are 5 RAV’s in PH (11-M-711, 11-M-712,11-M-713,11-M-714). These RAV’s are to
manually started only if

Drag chain conveyor 11-ONBCKT-001=1 (Customer scope) is running

11-M-716,11-M-717,11-M-718 is running.

RAV stopping: (To be implemented in TL Control system)

Stopping of the group of RAV’s (11-M-711, 11-M-712,11-M-713,11-M-714)can be initiated
by automatic stopping sequence or can be manually stopped one by one after the boiler
has tripped or shutdown.
RAV stopping sequence can be initiated:-
- Manually by operator OR
- Automatically when the boiler has tripped (i.e. 11-PHTRIP-001=becomes 1)
During auto sequence, the first All RAV is tripped after a delay of time 30 min.

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KURNOOL (FLUE GAS DAMPER OPERATION)

Subsequent to stoppage of all RAV’s, the DCC will be stopped. The sequence shall be as
follows.
11-M-711/712/713/714/715 11-M-716 (with 5 min delay) 11-M-717 (with 5 min
delay) 11-M-718 (with 5 min delay).

PH Boiler:
Force Close & Open condition:

1. Force close condition For inlet damper (11-XV-160):

Condition: Outlet damper close (11-XV-161). (Sensed by closed limit switch)
Reset force close condition: After getting close feedback of inlet damper (11-XV-
160).

2. Force close condition For outlet damper(11-XV-161):

Condition: Bypass damper open (11-XV-162). (Sensed by open limit switch) & Boiler Trip
(11-PHTRIP-001= becomes 1 to 0)
Reset force close condition: After getting open feedback of outlet damper (11-XV-
161).
3. Force open condition for Bypass damper (11-XV-162):
Condition: Boiler Trip (11-PHTRIP-001= becomes 1 to 0) OR Bypass selected.

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KURNOOL (FLUE GAS DAMPER OPERATION)

DAMPER OPERATION WRITE-UP-AQC BOILER

For AQC Boiler-1, the gas from the (Air quench) grate cooler kiln have two paths:-

For AQC-1 boiler, the dampers 12-XV-165 (Bypass damper), 12-XV-160 (Inlet damper),
and 12-XV-161 (Outlet damper) are motorized multilouver dampers and controlled from
customer DCS system.

AQC-1 Boiler Damper Operation.

There are three motorized dampers which will act as a group.

All these dampers will also have manual operation facility from the customer DCS system.

For group operation, dampers 12-XV-160, 12-XV-161, 12-XV-165 will act as a group and
open/close sequentially in case of boiler trip. When boiler is brought into service mode,
the dampers are brought into service manually one by one ensuring the permissive.

Boiler trip logic is implemented in TL control system and the CAUSES for Boiler trip are as
follows:-
i) LP drum low low
ii) HP drum level Low
iii) LP drum level high high
iv) HP drum level high high

In case Boiler trip is initiated in TL control system, following EFFECTS will be initiated:-
a. One Digital output (12-AQCTRIP-001=Incase BLR trip condition, becomes 1 to 0) to
initiate group bypass for the dampers 12-XV-160, 12-XV-161, 12-XV-165.
b. Initiate RAV trip sequence after 30 minute time delay. (RAV trip sequence logic to
be implemented in TL control system along with Drag chain conveyor logic.)

Bypass sequence for damper operation. (To be implemented in customer DCS

system)

The bypass sequence of dampers can be initiated manually from customer DCS by
operator or when boiler has tripped (if 12-AQCTRIP-001=becomes 1 to 0). The
completion of the sequence will ensure that the hot gases are bypassed to ESP suction
bypassing the boiler.

The sequence when started will follow the following steps

Step-1
Permissive - 12-AQCTRIP-001= Becomes 1 to 0

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KURNOOL (FLUE GAS DAMPER OPERATION)

Action: Force Open damper 12-XV-165 (Bypass damper) by forcing Open command until
getting OPEN F/B
Wait time: 40-60 secs (to be adjusted at site)

Step-2
Permissive – 12-XV-165 (Bypass damper) open sensed by open limit switch
Action:- Close damper 12-XV-161 (Outlet damper)
Wait time- 40-60 secs (to be adjusted at site)

Step-3
Permissive: Damper 12-XV-161 (Outlet damper) is closed sensed by closed switch
Action: Close damper 12-XV-160 (Inlet damper)
Wait time – 40-60 secs ( to be set at site)

Step-4
Permissive: Bypass sequence complete (One no Digital Output to be generated from
Customer DCS to TL control system), Digital O/P Tag: 12-BYP-002. (Where complete=1)

Action: Initiate RAV trip/stop sequence after 30 min time delay. (RAV trip/stop sequence
logic is to be implemented in PPPLC along with Drag chain conveyor logic.).Trip sequence
shall be as follows.

12-M-711/712/713/714/715 12-M-716 (with 5 min delay) 12-M-717 (with 5

delay)

Boiler Starting – Damper operation sequence (To be implemented in customer

DCS system)

During bringing the boiler in operational mode, we recommend that the dampers be
manually opened /closed one by one instead of running an auto-sequence.
Permissive for all following actions.

Common Permissive for Damper Opening operation are :

Boiler is ready for Damper opening Operation.
If 12-AQCBLR-RDY shall becomes o to 1 when

Drag chain conveyor (Customer scope) is running (12-ONDCH-001, one number
Digital out Put from Customer DCS system to TL Control system).

Drag chain conveyor 1 and 2 (12-M-700A, 12-M-700B) is running.

All RAV’s (12-M-711/712/713/714/715) is running.

Boiler has no trip condition includes LP /HP Drum level is healthy etc.
One number digital output shall be generated from TL control system to
customer DCS system as “Common permissive for damper opening
Operation” (12-AQCBLR-RDY, Ready=1)
After getting common permissive for damper opening following
sequence shall be executed in customer DCS system.

Step-1

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KURNOOL (FLUE GAS DAMPER OPERATION)

Permissive: 12-XV-165 (Bypass damper) open (sensed by open limit switch)

Action: Open 12-XV-160 (Inlet damper)

Step-2
Permissive: 12-XV-160 (Inlet damper) is open (sensed by open limit switch)
Action: Open 12-XV-161 (Outlet damper)
Wait till 12-XV-161 open feedback received.

Step-3
Permissive: 12-XV-160 and 12-XV-161 open
Action: Close 12-XV-165 (Bypass damper) gradually till minimum position is reached
sensed by limit switch.

BOILER ON signal is generated.

RAV starting (To be implemented in TL Control system)

There are 5 RAV’s in Boiler bottom. These RAV’s are to manually start only if.

Drag chain conveyor (Customer scope) is running(12-ONDCH-001=1)

Drag chain conveyor 12-M-716, 12-M-717 is running.

RAV stopping: (To be implemented in TL Control system)

Stopping of the group of RAV’s can be initiated by automatic stopping sequence or can be
manually closed one by one after the boiler has tripped or shutdown.
RAV stopping sequence can be initiated:-
-Manually by operator OR
-Automatically when the boiler has tripped. (i.e. 12-AQCTRIP-001=becomes 1 to 0 )

During auto sequence, the first All RAV is tripped after a delay of time 30 min.

Subsequent to stoppage of all RAV’s and DCC, the DO from PPPLC shall be triggered to 0
(i.e 12-AQCBLR-RDY= becomes 1 to 0).

The sequence shall be as follows.

12-M-711/712/713/714/715 12-M-716 (with 5 min delay) 12-M-717 (with 5 min
delay).

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KURNOOL (FLUE GAS DAMPER OPERATION)

AQC Boiler-1:
Force Close & Open condition:

4. Force close condition For inlet damper (12-XV-160):

Condition: Outlet damper close (12-XV-161). (Sensed by closed limit switch)
Reset force close condition: After getting close feed back of inlet damper (12-XV-
160).

5. Force close condition For outlet damper (12-XV-161):

Condition: Bypass damper open (12-XV-165) (Sensed by open limit switch) & Boiler Trip
(12-AQCTRIP-001= becomes 1 to 0)
Reset force close condition: After getting open feed back of outlet damper (12-XV-
161).
6. Force open condition for Bypass damper (12-XV-165) :
Condition: Boiler Trip (12-AQCTRIP-001= becomes 1 to 0) OR Bypass selected.

Note: All the timers shall be set at time as per commissioning requirement.

Note: Tag number has been revised and the same is marked in yellow.

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