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BOILER TRIP

A boiler trip command stops all fuel inputs by tripping


all of the pulverizers and feeders and closing all heavy
oil nozzle valves on all elevations.
There are two separate boiler trip commands in this
unit. Both no boiler trip command signals must be
established before a furnace purge cycle can be
initiated.
A boiler trip command will establish a master fuel
trip memory signal. This is indicated by the (red)
MFT TRIP light being on and the (green) MFT RESET
light being off.
When a master fuel trip memory signals established
(red, MFT TRIP light is on),
The following events occur:
1. The (red) MFT A TRIP and MFT B TRIP lights come
on and the associated (green) MFTA RESET and MFT
B RESET lights go off.

3. The boiler load greater than 30 % memory signal is


removed.
When the master fuel trip memory signal is
established (red, MFT A TRIP or MFT B TRIP LIGHT IS
ON), the following events occur:
4. Both of the (red ) BOILER TRIP light come on and
the PUSH TO PURGE AND PURGING light are
armed.
5. The PULV MODE (green) MANUAL light comes on, if
it was off.
6. All pulverizers are tripped as indicated by the PULV
START PERMITS (white) NO PULV TRIP lights going off.
7. A five minute counting period is started. Five minutes
latter, all cold air dampers are opened to the 100 %
pulverizer air flow position.
8.The permit to start P.A. fans signal is removed.
9. The oil elevation trip memory signal is established

11. A five second counting period is started. Five


seconds later, the loss of fuel trip arming signal is
removed.
12. The CAUSE OF TRIP memories cannot be reset.
13. All feeders are shutdown.
14. The upper and lower fuel air dampers are opened.
15. The auxiliary air control is transferred to MANUAL
control and all auxiliary air dampers are opened.
16. The primary air (P.A.) fans are tripped.
17. The feed forward to furnace draft control signal is
established for thirty seconds if the following conditions
are satisfied:
A. The unit critical power is available for more than six
seconds AND
B. The loss of fuel trip arming signal is established.
When this signal is established, item B is no longer
required to keep this signal established.
Thirty seconds later, the feed forward to furnace draft

When the thirty second counting period expires, the


furnace pressure
Recorder will remain at the higher speed if a high
furnace pressure alarm or a low furnace pressure
alarm signal is established. When both of these signals
do not exist for more than thirty seconds, the furnace
pressure recorder reverts to its original speed. The
recorder will revert to the higher speed if either of these
signals are established.
A boiler trip signal is established if any of the following
conditions exist:
19. Loss of ACS power for more than two seconds.
20 Loss of customers 220 VDC Battery power for more
than 2 ) seconds.
21. Loss of unit critical power for more than two
seconds.
22. A simulator trip signal exists.
23. The water drum level is low for more than ten

27. All I.D. (Induced Draft) fans are off.


28. ALL F.D. (Forced Draft) fans are off.
29. The air flow is less than 30 % before the boiler load
exceeds 30 %.
30. The deaerator level is low-low.
31. At least two of the three pressure switches indicate a
high furnace pressure trip condition.
32. At least two of the three pressure switches indicate a
low furnace pressure trip condition.
33. Both BOILER TRIP (emergency) push buttons are
depressed simultaneously.
34. All feeders are off and loss of power exists at the
elevation that is in service.
35. A loss of reheat protection occurs.
36 A loss of fuel trip signal is established (see Note
below).
Note : The loss of fuel trip signal becomes armed
when the first oil elevation that is placed in service has

After the loss of fuel trip signal is armed, a loss of


fuel trip signal will be established if all of the following
conditions occur simultaneously:
A. At all coal elevation, the feeder is off or loss of
elevation power exists. This condition exists for more
than two seconds
AND
At all four oil elevations all oil nozzle valves are closed
or an elevation trip signal is established at the
associated oil elevation.
The loss of fuel trip signal is proven established when
the Data Logger receives a LOSS OF ALL FUEL TRIP
signal.
B. At all coal elevations, the feeder is off or loss of
elevation power exists. This condition exists for more
than two seconds.
AND
The heavy fuel oil trip valve is not fully open

The Data Loggers LOSS OF ALL FUEL TRIP signal will


remain established if item B above is satisfied. When
the heavy oil trip valve is proven fully open (for oil
recalculation), this signal is removed.
37. A unit flame failure signal is established (see Note
below).
NOTE : During light off and before any feeder is
proven for more than two seconds, the fireball
flame scanners do not take part in the overall flame
failure protection systems. When any feeder is proven
for more than two seconds, the system automatically
changes from flame failure protection of an individual
fuel nozzle to a FIREBALL supervision of the furnace.
The system is designed to initiate a boiler trip when
any feeder is proven for more than two seconds and all
five fireball flame scanner elevations vote no flame
simultaneously.
After any feeder is proven for more than two seconds,

This is indicated when the Data Logger receives a


FLAME FAILURE TRIP signal. This signal causes a
master fuel trip memory signal to be established
(both (red) BOILER TRIP lights come on).
When each fireball flame scanner elevation votes no
flame, the associated UNIT FLAME FAILURE (amber)
light comes on at the associated fireball flame scanner
elevation. Listed below are the conditions that will
cause this (amber)light to be illuminated for the various
fireball flame scanner elevations.
Elevation AB:
1. Feeder A is off or loss of elevation A power and
Feeder B is off or loss of elevation B power. This
condition exists for more than two seconds. OR
2. At elevation AB, less than three of the four heavy fuel
oil nozzle valves are fully open or fuel flow is not
adequate at the associated oil nozzle valve or elevation
AB power is not available for more than two seconds

3.At elevation AB, less than three of the four heavy fuel
oil nozzle valves are fully open or fuel flow is not
adequate at the associated oil nozzle valve or elevation
AB power is not available for more than two seconds
and any elevation AB heavy fuel oil nozzle valve is not
closed or elevation AB power is not available for more
than 2 seconds.
Elevation BC:
1. Feeder B is off or loss of elevation B power and
Feeder C is off or loss of elevation C power. This
condition exists for more than two seconds.
2. Less than two of the four fireball flame scanners
indicate flame on elevation BC.
Elevation DE:
1. Feeder D is off or loss of elevation D power and
Feeder E is off or loss of elevation E power. This
condition exists for more than two seconds.
2. Less than two of the four fireball flame scanners

Elevation FG:
1. Feeder F is off or loss of elevation F power and Feeder
G is off or loss of elevation G power. This condition
exists for more than two seconds.
2. Less than two of the four fireball flame scanners
indicate flame on elevation FG.
3. One elevation GH, any heavy fuel oil nozzle valve is
not closed or elevation GH power is not available for
more than two seconds.
Elevation GH:
1. Feeder G is off or loss of elevation G power and
Feeder H is off or loss of elevation H power. This
condition exists for more than two seconds. OR
2. At elevation GH, less than three of the four heavy
fuel oil nozzle valves are fully open or fuel flow is not
adequate at the associated oil nozzle valve or elevation
GH power is not available for more than two seconds
and less than two of the four fireball flame scanners

3. At elevation GH, less than three of the four heavy fuel


oil nozzle valves are fully open or fuel flow is not
adequate at the associated oil nozzle valve or elevation
GH power is not available for more than two seconds and
any elevation GH heavy fuel oil nozzle valve is not closed
or elevation GH power is not available for more than
2 seconds.
CAUSE OF TRIP SYSTEM
A Cause of Trip system has been incorporated which
allows the Operator to determine the cause of a master
fuel trip which was initiated by a boiler trip command.
The boiler trip commands that can cause a master fuel
trip memory signal to be established .
The first boiler trip command that causes a master fuel
trip (both (red) BOILER TRIP lights come on), will
illuminate the appropriate indicator in the CAUSE OF
TRIP section on the console insert. The Data Logger will
also receive a corresponding signal.

When the furnace purge cycle is successfully completed


(PURGE CYCLE (yellow) PURGE COMPLETE light is on)
and a no master fuel trip memory signal is
established (both (red) BOILER TRIP lights are off), all
CAUSE OF TRIP memories are reset and there are no
illuminated indicators.
POST PURGE EXCURSION PROTECTION
A post purge excursion circuit has been designed into
the Furnace Safeguard Supervisory System. It operates
as described below:
1. During the Furnace Purge Cycle, the following
conditions are satisfied:
A. The mode permit is satisfied
B. All heavy fuel oil nozzle valves are closed
C. The heavy fuel oil trip valve is closed,
D. All pulverizers are off
E. All feeders are off
F. All flame scanners (discriminating and fireball)

2. When all of these conditions are satisfied


simultaneously, a five minute counting period is started.
After the five minute counting period expires, the
following events will occur:
A. A post purge time expired memory signal is
established and a post purge fan trip signal is
established if a high or low furnace pressure trip signal
is established.
This is indicated when the Data Logger receives a
FURNACE PRESSURE HIGH or a FURNACE PRESSURE
LOW signal.
The post purge fan trip signal is proven established if
the Data Logger receives POST PURGE FAN TRIP signal.
If this signal is established, the I.D. and F.D. fans are
tripped.
B. The open upper fuel air dampers memory signal is
removed, closing the upper fuel air dampers.
Simultaneously, a thirty second counting period is started.

When the five second counting period expires, the


auxiliary air dampers are now released from manual to
the auxiliary air control system and the open auxiliary
air dampers signal is removed.
When any heavy fuel oil elevation has at least three of
the four oil nozzle valves fully open, the post purge
time expired memory signal is removed which will now
prevent the post purge fan trip signal from being
established. When the heavy oil trip valve is moved
form the closed position (for oil recalculation), the five
minute counting period is reset.

Boiler Emergencies
Procedures during the following emergency
conditions
1. Boiler Explosions
2. Boiler Implosions
3. Low Water Level
4. High Water Level
5. Boiler Tube Leaks
6. Master Fuel Trip
7. Reheater Protection Trip

Boiler Emergencies
Emergency boiler procedures :
A) Boiler explosions
a. Causes
1. Furnace explosions can be caused by an accumulation of
unburned fuel in the furnace due to incomplete
combustion, loss of ignition, or fuel valve leakage.
2. With a mixture of unburned fuel with air in explosive
proportions, and the application of heat sufficient
enough to raise the temperature of the mixture to the
ignition point, explosions can occur.
3. The accumulated fuel is ignited resulting in a greater
than normal pressure increase.
4. The fuel may enter the furnace in the unburned state in
a number of ways, for instance:
a) Through leaky main fuel or ignition fuel inlet valves on
idle wind box/burner compartments.

Boiler Emergencies
b) If the fires are extinguished and the if the fuel is not shutoff
promptly.
c) If the fuel is not burning as rapidly as rapidly as it is entering the
furnace.
d) In starting up, if difficulty is experienced in establishing ignition.
b. Prevention
1) During start-ups maintain a high air flow (up to 30% of full load air
flow) to ensure an air rich furnace atmosphere and prevent
accumulation of explosive mixtures.
2) Be sure that the main fuel and ignition fuel inlet valves on idle
fuel compartments or burners are closed tightly and do not leak.
It is advisable to remove idle oil guns from the guide pipes, to
avoid dripping.
3) Watch the fires so that the fuel may be shut off without delay if
extinguished unexpectedly. If the fires are lost, trip all main and
ignition fuel immediately. Close all trip and fuel shut off valves.
Purge the furnace at least for 5 minutes after shut down with 30%
(minimum) air flow.

Boiler Emergencies
4) When a boiler has been idle, purge the furnace before putting
igniters in service. Be sure that the warm up fuel firing rate is high
enough to produce a flame not easily extinguished.
5)Always use an associated igniter to light off a main oil or gas
nozzle.
6) Regularly check proper function of FSSS or BMS (interlocks,
trips)
B) Boiler Implosions : Destructive negative pressure.
a. Causes
1) Tripping or sudden loss of fuel results in mass temperature
reduction resulting in rapid decrease in furnace pressure.
2) Rapid evacuation of heated gases by ID fans.
3) Failure of fan controls.
b. Prevention
1) The air flow to the furnace must be maintained at its pre trip
value and must not be prevented from increasing by following
natural fan curves; but positive control action to increase air
flow is not allowed.

Boiler Emergencies water levels


2) The flow of combustion products from a furnace must be
reduced as quickly as possible following a unit trip.
3) If the removal of fuel from the furnace can be over a 5 to
10 seconds period (rather than instantaneously) there will be
a reduction in the magnitude of a furnace pressure excursion
that follows a unit trip.
4) Further prevention of implosion can be accomplished by
keeping protective control systems in proper working order
and well tuned.
C. Low Water Level
a. Causes
1. Control failure
2. BFP failure
3. Tube leaks
b. Action
1) Compare indication.

Boiler Emergencies- water levels


2) If the water level falls out of sight in the water gauge, due to
failure of the feed water supply or neglect of the operator, except in
cases of momentary fluctuations that might occur with extraordinary
changes in load, appropriate action should be taken at once to trip
the fuel. Any decision to continue to operate, even if only for a short
time at a reduced rating, would have to be made by someone in
authority who is thoroughly familiar with the circumstances that led
to the emergency and positively certain that the water level can be
restored immediately without damaging the boiler. In the absence of
such a decision :
a) Trip all fuel immediately.
b) Shut off all steam discharged from the unit( trip turbine, steam
driven auxiliaries etc.)
c) Simultaneously, if feed water has become available and the
operator is assured that no pressure parts have been damaged,
gradually reduce the flow of feed water to the boiler by manual
regulation. This will avoid quenching of hot pressure parts with
relatively cold water. The feed water regulating valve should be
closed completely when all the steam flow from the unit has
ceased.

Boiler Emergencies-water levels


d) Maintain a high air flow at first to hasten the cooling process.
e) If pressure parts damage is suspected, reduce the main steam
pressure gradually by opening the super heater startup drain. Open
the drum vents when the pressure drops below 1.75 bar. As the
boiler cools, reduce the air flow. Shut down the fans as soon as the
unit is cool enough for a man to enter. Drain the boiler when the
drum metal temperature is 93C. Determine the cause of low water
and examine the boiler for the effects of possible overheating such
as leaks and distortion of pressure parts.
D. High Water Level :Water impingement may cause turbine
damage.
a. Causes
1) Feedwater control malfunction
2) Operator error
b. Action
1) Abnormally high water level should be avoided as it may lead to
carryover and even priming. If the water level rises above rises
above the recommended normal operating range proceed as
follows

Boiler Emergencies-water levels


a) Reduce the water level immediately by opening the
intermittent
blowdown valves.
b) Reduce the steam rate, if necessary, and place
feedwater control on
manual.
2) If priming should occur, as indicated by rapid
fluctuations in outlet steam temperatures in outlet steam
temperature, proceed as follows:
a) Reduce the steaming rate.
b) If the water level is abnormally high, reduce the level
by opening the intermittent blowdown valves and
place feedwater control on manual.
c) Investigate the water condition (alkalinity and solids)
d) Investigate the condition of the drum internals as soon
as an opportunity is afforded.

Boiler Emergency-Tube failure


Boiler tube failures : Operating a boiler with a known tube
leak is not recommended. Steam or water escaping from a
small leak can cut other tubes by impingement and set up a
chain reaction of tube failures. By the loss of water or steam, a
tube failure can alter boiler circulation or flow and result in
other circuits being overheated. A tube leak can also cause
loss of ignition and, if reignition occurs, a furnace explosion. An
investigation of tube failure is very important so that the
conditions causing the tube failure can be eliminated and
future failures prevented.
The investigation should include a visual inspection of the
failed tube. In some cases a laboratory analysis or
consideration of background information leading up to the
tube failure is required. This information should include the
location of the failure, the length of time the unit has been in
operation, load conditions, start up and shutdown conditions,
and feed water treatment.

Boiler Emergencies-tube leaks


5.
a.
1)
2)
3)

Tube Leaks
Indications of the tube leaks are
Feedwater flow greater than steam flow
Excessive desuperheater flow
Wetted insulation of water running down casing with no
apparent cause.
4) Excessive make up.
5) Noise from the boiler (Acoustic noise level indicators)
b. Action
6) Furnace tube leaks
a) The action taken is dependant on the size and location
of the tube leak
1) A large leak may extinguish fire or cause loss of drum
level.
2) A medium size leak may force an immediate shut down.

Boiler Emergencies-tube leaks


3) A small leak may allow continued operation after considering
its consequences on continued operation.
b) If at all possible locate the leak
c) In the vent of failure of one or more water carrying tubes, the
best method of shutting down the unit will be dictated by the size
of the failure, the ability to maintain normal water level and the
demands for the service of the unit.
d) The following instructions regarding tube failures are of general
nature. It must be understood that conditions may arise which will
require exercise of judgment by the operators.
e) In case of a leak or tube failure which does not involve a
serious drain on the feedwater supply, the water level should be
maintained and the unit taken out of service in the normal
manner.
f) If the tube failure results in a loss of water so great that the
water level cannot be maintained with the feedwater supply
available, use the method outlined below.
1) Trip all fuel

Boiler Emergencies-tube leaks


2) Shut off feedwater to the boiler.
3) Maintain only enough air flow to carry the escaping steam up the
stack.
4) Leave the fans in service until pressure is off the unit.
g) After the unit has cooled enough to permit a man enter it, make a
thorough inspection of pressure parts for any indication of damage
resulting from loss of water level. After the necessary repairs have
been made, apply a hydrostatic test and obtain the approval of the
proper authorities before putting the unit back in service.
2) Economizer Tubes
a) An economizer tube leak can be detected by sound and/ or
increased make up water requirements. The leak should be
detected at the earliest possible time and the unit shutdown in the
normal manner.
b) Water leaks in the economizer can cause considerable erosion
damage to the adjacent tubes. Water carried over from
economizer tube leak may cause plugging of hoppers and
airheaters.

Boiler Emergencies-tube leaks


3) Super heater Tubes
a) A small leak in a superheater element should be investigated
at the earliest possible time, and the unit should be shut down in
a normal manner. Steam leaks in the superheater can cause
considerable erosion damage to the adjacent tubes. Any decision
to continue operation with leaks should be made this in mind.
b) A major superheater tube failure may require an emergency
unit shutdown.
6. Master Fuel Trip
a) Under conditions requiring a master fuel trip through normal
interlocks or operators action (manual trip), all fuel should be
tripped instantaneously.
b) The following steps should be taken immediately following an
emergency fuel trip.
1) Maintain the unit air flow at the pre-trip value for at least 5
minutes to purge the system.
2) Check to ensure that all the fuel nozzles shut off valves are
closed.

Boiler Emergencies-tube leaks


3) If all auxiliary power sources are lost during a trip, upon
restoration of power, start the ID and FD fans and purge
the furnace for five minutes.
Other boiler emergencies
Air preheater fires/tripping of APH ( one fan operation)
Coal mill explosions ( may lead to boiler trip)
Loss of furnace seal
Loss of scan supply of any elevation
Loss of instrument air
Loss of cooling water to scaffold door
Bending of long retractable soot blower / furnace probe

Reheater Protection
Boiler will trip when any one or more of the following
conditions occur :
1. Turbine Tripped or Gen CB open and HP or LP
Bypass valves opening < 2% then after 5 sec of Time
delay.
2. Turbine working (control valves >2 %) and Load
shedding relay actuated and if HP or LP Bypass
opening is < 2 %,
Reheat protection will act after 10 sec. delay.
3. If Turbine is not working (HP or IP control valves <
2%) and boiler working (No. contact of loss all fuel
arming relay from FSSS) and HP or LP Bypass valves <
2 % with a time delay of 5 Sec.
Reheat Protection will act.
Arming of Reheat Protection -Once HP & LP Bypass are
open 2 % and steam flow increases beyond 200T/hr

BOILER TRIP Causes


With the exception of the operator push button trip, following conditions
will automatically generate Master Fuel Trip (MFT)
Loss Of All ID Fans
Loss Of All FD Fans
Less Than Two Circulating Pumps Running
Circulating p Less Than 0.6 Bar
Drum Level Low-low (-330 mm).
Furnace Pressure More Than 330 Mmwc Or Less Than -250 Mmwc
Loss Of All Fuel
Air Flow Less Than 30%
Turbine Trip
Reheater Protection Trip
Unit Flame Failure
Loss Of Unit Logic Power
Emergency Push Button.
Cause of trip system : The first boiler trip command that causes a MFT
will illuminate the appropriate indicator in the cause of trip section on the
console insert. Any successive boiler trip commands to the other indicators
are blocked. There will be only one indicator that will be glowing

Turbine protections
1. LOW VACUUM
( Hyd trip > 0.3 bar, electrical trip > 0.3bar)
2. HIGH AXIAL SHIFT
( 1.0 mm)
3. OVERSPEEDING OF TURBINE
( Mechanical Trip3330 rpm, electrical trip >3330 rpm)
4. MAIN OIL TANK LEVEL LL( fire protection 2)
( 1030 mm from top)
5. C. F. TANK LEVEL LL( fire protection 1)
( -115 mm )
6. LOW LUBE PRESSURE( A 4.8 bar,T 2.2 bar)
7. CONTROL OIL PRESSURE( T 3.5 bar)
8.TURBINE REMOTE PUSH BUTTON TRIP
9.FIRE PROTECTION 1 & 2(PUSH BUTTON)
10.BOILER TRIP LEADING TO TURBINE TRIP
11.GENERATOR TRIP LEADING TO TURBINE TRIP

Turbine protections
TURBINE ADVISORY TRIP
1. HIGH SHAFT VIBRATION / ECCENTRICITY
( A 120mic,T 200 mic)
2. HIGH BEARING VIBRATION
( A 35 mic,T 45mic)
3. HIGH BEARING METAL TEMPERATURE
( A 90C,T 120C)
4. HIGH DIFFERENTIAL EXPANSION
(HP -3/5mm,IP -2/7mm,LP -3/30mm)
5. HIGH/LOW MAIN STEAM TEMPERATURE
6.HIGH DRUM LEVEL

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