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DISCUSSION

ON
FURNACE SAFE
GUARD SUPERVISORY
SYSTEM (FSSS)

LOGIC

By R.N MANIK

INTRODUCTION
THE SAFE OPERATING PROCEDURE AND
EXECUTION OF SAFE SEQUENCE IN THE START UP
AND SHUTDOWN OF FUEL FIRING EQUIPMENT IS
BEING ENSURED BY THE FURNACE SAFEGUARD
SUPERVISORY SYSTEM (FSSS)
THE SAFETY FEATURES OF THE SYSTEM ARE
DESIGNED FOR PROTECTION IN MOST COMMON
EMERGENCY SITUATION OR ANY MALFUNCTION
OF FUEL FIRING SYSTEM.
IN NORMAL OPERATION THE FSSS LOGIC
PROVIDES PERMISSIVE INTERLOCKS TO ENSURE
SAFE START UP OF EQUIPMENT
COMBUSTION ENGINEERING DEMANDS ALL
PROTECTION IS TO BE IN SERVICE FOR SAFE
OPERATION OF BOILER IN CASE OF ANY
ABNORMALITY.

FURNACE SAFEGUARD
SUPERVISORY SYSTEM COMPRISES
THE FOLLOWING OPERATIONAL
FUNCTION

Furnace purge supervision


SADC modulation
Light oil control & protection
Pulverisers & feeders control and
protection
Flame scanner monitoring
Boiler trip report

Architecture of FSSS PANEL


Flame scanner
MFT
Unit
Oil AB & coal A & B
Oil CD & coal C & D
Oil EF & coal E & F
SADC
Soot blower

GUS1

GUS2

GUS3

GUS4

GUS5

GUS6

GUS7

PHD

TH L SYSTEM

OP ERA TIN G
STATION S

HM

AM

NIM

UCN 2

LCN

NIM

UCN 1

LM1

LM2

LM6

LM7

LM8

HP M1

SI

HP M5

MOD IF IC ATION

HADWARE SIGNAL EXCHANGE


BHEL SY STEM

OP ERA TIN G
STATION S

HU B
HU B

SERVER1

TSE

LPBP

EHTC

DRIV E

HP BP

SA DC

SB

E&F

C&D

A$B

DS

SERVER2

WSPO SE
IPB1
IPB2

FLAME SENSING SYSTEM


Flame sensing system are of two types
1.Safe flame-II
2.Safe flame-I
SAFE FLAME-II
It is designed to detect the presence of
flame in the Furnace from two different
sources using the same scanner head.
This will discriminate between an
individual oil gun flame and background
fireball flame. This is achieved by
sensing frequency and intensity of oil &
coal flame.

SAFE FLAME-I
It is designed to detect the presence of
flame in the Furnace from one source by
scanner head. This will sense only
background fireball flame through
characteristics
of
frequency
and
intensity.

SCANNER SCHEME

BOILER
FLAME

Fiber
optic cable

Boiler mounted electronics


converts light to
current signal
Current to voltage
Intensity
detector

Frq. detector

Fault
detector

100
50

Frequency

Intensity

Meter

Flame

Fault

COAL FLAME SIGNAL DISTRIBUTION ACROSS


THE MFT PANEL
FLAME SIGNAL
FROM FLAME SCANNER PANEL
IN THE FORM OF 2V4

INPUT
CARD OF
UNIT
PANEL

INPUT
CARD OF
MFT-1
INPUT
CARD OF
MFT-2
INPUT
CARD OF
MFT-3

OIL FLAME SIGNAL DISTRIBUTION ACROSS


PANEL
OIL FLAME SIGNAL
FROM FLAME SCANNER PANEL

INPUT
CARD TO
INDIVIDUAL
OIL
ELEVATION

Post Purge fan trip

furnace pressure very low


/very high during purging

LIGHT OIL TRIP VALVE


PERMISSIVE
ALL ELEVATION LO VALVES CLOSED
LFO HEADER PRESSURE ADEQUATE
NO MFT
LOTV CLOSE COMMAND NOT THERE
OR
LORV OPEN

LOTV CLOSE COMMAND


LOTV OPENED
AND LFO PR. VERY LOW
OR
MFT
WITH LORTV CLOSED

LIGHT OIL RECIRCULATION TRIP


VALVE
This is basically used for recirculating light oil for
long recirculation after opening LOTV.

LO ELEVATION START
Light oil elevation can be fired
independently or through pair mode in
diagonally opposite corner (1&3 /2&4)
provided coal feeders are in off condition.
Pair mode

Start
Elevation mode

Elevation mode of operation


This mode of operation can be established on either
adjacent feeder associated with the LO elevation is
proven.
On elevation start command,
Which will persist up to 70 sec.
if 3 minimum of 4-nozzle valve at that elevation
are open then the elevation mode is successful
Otherwise unsuccessful elevation start alarm is
initiated. This will stop one pair in 40 sec after
other.

UNSUCCESSFULL STARTUP OF OIL ELEVATION

Pressing associated pair starts will initiate 70-sec start time to place
the associate pair of oil guns in service
Once start command is sent to single corner in pair mode after 15
sec opposite corner start initiates.
If the flame is established within the above 15 sec then the oil gun
is said to have been successfully placed in service. If fails within
said time corner trip will be initiated which will close the corners
valve of particular corner.
At the end of 70 sec oil corner trip is initiated in any corner of that
elevation , the unsuccessful start up will appear in ann.

PULVERISER
START(Manual
Mode)
The following are the per missives of
Pulveriser to start manually by
operator.

PULVERISER START PERMIT


Seal air header to bowl DP adequate more
than 200mmwc
And Pulveriser ready
And respective Pulveriser permits
available
And Pulveriser motor off

Primary air permit


1. Both FD fan and pa fan on
2. Any FD fan and pa fan on and 2 mills are
running with pa header pressure adequate.

PULVERISER READY
Before starting mill, Pulveriser ready
permissive is one of the criteria which is
achieved under following conditions:
a. Pulveriser /feeder start permit
b. Pulveriser discharge valve open
c. Pulveriser outlet temp. not high
d. Cold air gate open
e. No auto Pulveriser unsuccessful start
f. Tramp iron hopper valve open
g. Pa permit available
h. Bunker o/l gate open and feeder inlet gate
open
i. All coal burner manual isolation valve open
j. No Pulveriser trip command
When all the above conditions are satisfied for
the respective Pulveriser, its associated
Pulveriser ready condition is satisfied.

Pulveriser ignition permit


1. Corresponding oil elevation in service
OR
2. Boiler load more than 30% and adjacent mill
load more than 50%

Feeder start permit


any feeder proven
burner tilt horizontal and air flow more
than 40%

PULVERISER START (Auto Mode)


Permissive: Pulveriser ready
AUTO
MODE

A 180 SEC COUNTING PERIOD IS STARTED


TO PROVE THE ASSOCIATED
PULVERISER/FEEDER IN SERVICE

AUTO START
SUPPORT
IGNITION

CMND TO
ASSOCIATED
LO
ELEVATION

AUTO START
MILL AND
HOT AIR

GATE

AUTO START
FEEDER

PROVIDED HOT AIR GATE OPENING


WITH TEMP NORMAL>200 DEG F

UNSUCCESSFUL ELEVATION START

In whole process after the 180-sec


elevation start counting period expires
and the mill is ONand feeder is OFF,
the unsuccessful elevation start is
established. When the feeder is off more
than three minutes, the mill receives an
auto stop mill command and is
shutdown.

PULVERISER TRIP
MFT
SEAL AIR HEADER PRESSURE TO BOWL
DPLESS THAN 125 MMWC
PULV IGNITION IS NOT THERE BUT
IGNITION SUPPORT IS REQUIRED.
PULV. DISCHARGE VALVE CLOSED
ANY OF BURNER MANUAL ISOLATION
VALVES NOT OPEN
LOSS OF PRIMARY AIR
PULVERISER IGNITION SUPPORT REQUIRED FOR 3 MINUTES
AFTER ANY ONE OF THE FOLLOWING INCIDENCE S

a. On initial startup of feeder


b. Feeder start command given after its permissive but due
to some reason feeder could not take start.

Loss of primary air


Hot pa pressure very low
or
Both PAfans off and any
pulv. on

PA fan start permit


1.all elevation cold air dampers open
less than 5 % and
2.purge over
or
any pa fan on

Seal air valve auto start


Sa header to cold air duct DP low and
any PA Fan On
Unsuccessful start of seal air fan
Command is issued from logic either from
backup console by engineer or through
auto logic and fan could not started due to
any other reason after 5 sec.

SIGNAL DISTRIBUTION IN MFT PANELS


1
2 ONE SIGNAL

SIGNAL DISTRIBUTION

3
MFT-1

MFT-1
RELAYS

MFT-2

MFT-2
RELAYS

MFT-3

MFT-3
RELAYS

MFT1
MFT2
MFT1

MFT2
MFT3
MFT3

1. INPUT SIDE
A.
SIGNAL FROM FIELD IS ACQUIRED FIRST IN SIGNAL
DISTRIBUTION CARD, FROM WHERE THESE SIGNALS ARE
DISTRUBATED
TO
INDEPENDENT
MFT
THROUGH
HARDWARE CONNECTION.

EXAMPLE:
FURNACE PRESSURE VERYHIGH 1/2/3

SIGNAL CONDITIONING CARD

MFT-1

MFT-2

MFT-3

Reheater Protection Trip


ARMING ON ANY FEEDER ON
ON GENERATOR CIRCUIT BREAKER OPEN
HPBP valve opening must be more than 2 %
And
LPBP valve opening must be more than 2 %
ON GENERATOR CIRCUIT BREAKER
CLOSED
HPBP valve opening must be more than 2 % or any
HPCV valve opening is >2%
LPBP valve opening must be more than 2 % or any
IPCV valve opening is >2%

UNIT FLAME FAILURE TRIP


ARMING : ANY FEEDER ON
ALL ELEVATION VOTING
ELEVATION VOTING
ANY OIL ELEVATION NOZZLE VALVE
3 OUT 4 IS NOT PROVEN
AND
AND RESPECTIVE FIRE BALL IS NOT
THERE
OR
FEEDER OFF
OR
FIRE BALL IS THERE AT ELEV. BUT 110VAC
NOT AVAILABLE ON OIL START COMD.

Secondary
operation

air

dampers
.

On MFT
a. Open upper fuel
dampers and lower fuel
dampers elev. a,b.c d,e &f
b. Open upper ofa dampers
c. Open lower ofa dampers
d. Transfer aux. control to
manual

ON FEEDER STOP
CLOSE CORRESPONDING FUEL DAMPER
ON MILL OFF AND BOILER LOAD >30%
CLOSE CORRESPONDING AUXILLARY
AIR DAMPERS

FDR SPEED~FUEL DMPR PSN

FUELDAMPER
POSNACT.

25
20
15
10
5
0
0

25

60

FEEDER SPEED

100