Furnace Safeguard Supervisory System

(FSSS)

FSSS is designed to ensure the execution of safe, orderly operating sequence in start-up and shutdown of boiler to prevent error of omission in following operating procedure. FSSS is logic system and interlocks specially meant for increasing safety, reliability, flexibility, overall performance of boiler and protection against malfunction of fuel firing equipments and associate air system Functions -Furnace Purge Supervision -H.O. gun start, stop, supervision. -Mill and feeder starting, stopping, supervision -Secondary and fuel air damper control. -Flame scanner intelligence and checking. -To trip out boiler fire and other equipments when boiler safety is threatened.

FSSS Equipment can be grouped under three heads 1- The Operating and Indicating Console Insert in UCB- consists of all switches and indications of all fuel firing equipments and auxiliaries. 2- Relay and Logic Cabinets- consist of relays, timers, programmers, circuit breakers for AC and DC control supply, flame scanner unit, SADC control, Mill panels, Oil gun panel. They control the process logic. Logic is functionally divided into Unit logic, elevation logic, and corner logic. 3- Field Equipments-consist of equipments which help in actual remote operation of fuel firing equipments and provide the status to operating console and relay logic cabinet. Field equipment includes-HOTV, HORV, atomising steam valve, nozzle valves, scavenging valve, gun/ ignitor advance retract mechanisms, ignitor/gun cabinets, local/remote/scavenge switch, flame scanner, pressure switches, temp. switches, limit switches. Mill discharge valves, HAG,CAD, tramp iron gate, seal air valve, SADC etc.

Furnace Purge

Furnace purge is required after a boiler trip-out and before re-light up of boiler to expel all unburnt fuel particles, gas, vapour etc. from the boiler, so that possibilities of explosion are avoided, when boiler is lighted up. To start furnace purge cycle -Establish AC and DC power to FSSS and related equipments. -Establish normal drum level. -Place at least one ID and one FD fan running and air flow between 30-40%. -Depress the PURGE START button. Purging will continue for 5 minute if purge ready condition are fulfilled and PURGE COMPLETE will glow. Purge Ready Conditions -HOTV close. -All HONV close. -All pulverisers off. -All feeder off. -All HAG closed and CAD in minimum open position. (<5%) -All SADC modulating to maintain an adequate windbox to furnace DP. -Auxiliary air dampers on auto. -All elevation flame scanner show No Flame. -No boiler trip command is persisting. Heavy oil on-off control and supervision.

Heavy oil recirculation- for maintaining proper fuel oil temp. at firing elevation, heavy oil is recirculated by means of HORV and HOTV. -Before purging first HORV will open if all HONV are closed, then HOTV will open. -HORV will get auto closed when any HONV open. -After purging HOTV will open if heavy oil supply pressure/temp. is adequate, all HONV close. -HOTV will auto closed if oil supply pressure/temp. is low, atomizing steam pressure is low or boiler trip occur Oil Gun start/ stop Elevation start permit conditions-purge complete, oil temp. adequate, HOTV open, airflow<40%,Burner tilt horizontal. Corner oil gun start conditions-local switch in remote, oil and steam manual isolating valves open, gun is engaged, scavenge valve close. Oil gun start sequence-Depressing Pair Start button will initiate a 90 second start time trial as follow.(for pair 1-3) -A Start command is sent to oil corner1. -25 second later, start command is sent to oil corner 3 -When individual corner (gun) get start command, gun is place in service in following sequence:- gun fully advance, ignitor fully advance, atomizing steam valve open, HEA spark energize, oil valve open, flame establish and sense by scanner -10 second after oil valve is opened, HEA gets retracted -At the end of 90 second oil corner trip command is initiated for any corner if gun is not proven.

-Oil gun shutdown sequence-Depressing Pair stop button will initiate 375 time trial as follows. -Stop command is sent to corner 1, -25 second latter stop command is sent to corner 2 -when individual gun receive stop command scavenge cycle is initiate in following sequence:-HONV close, scavenge valve open, HEA advance, spark energise for 10 second , HEA retract, -At the end of 5 minute scavenge period, scavenge valve and atomizing valve close and gun gets retracted.

Mill and feeder start, stop and supervision Pulveriser Ready Condition
-Pulveriser discharge valve open. -Seal air valve open. -CAG open -Mill outlet temp. normal <95 -Tramp iron gate open -PA permit -Feeder local selector on Remote -Any seal air fan on -No pulveriser stop command -Start permit -Ignition permit -Pulveriser Ready.

Ignition energy-Prior to starting ignition energy must be adequate to support coal firing which is accomplished as follows -At a particular elevation 3 out of 4 oil guns proven. Or Boiler loading is greater than 30% and adjacent mill in service at greater than 50% loading. Pulveriser start sequence- Start pulveriser, open HAG and adjust airflow and temp., start feeder and adjust loading. Feeder start permissive-feeder speed minimum, Pulveriser on, Mill outlet temp more than 60, coal silo gate open,Fuel air damper close, all pulveriser permissive HAG/HAD/CAD interlocks-HAG close if mill outlet temp.>95 or feeder trip or mill trip

Flame scanner intelligence- Consist of -Scanner air fan control-AC/DC scanner take auto start if scanner air pressure is<115mmWC. -Flame scanner output indication-If 2/4 fire ball scanner sense flame and any one associated feeder is on flame indication glows. -Flame failure Trip- the boiler FLAME FAILURE protection become ARMED when any one coal feeder is proven. This protection will be actuated if on all elevation No fire ball condition is present for >2sec Secondary air control

Auxiliary air Damper-During furnace purge and up to 30% loading, all elevation auxiliary damper modulate to maintain predetermined(40mmWC)DP between windbox and furnace. -At load more than 30% DP set point ramps to 100mmWC simultaneously aux. air dampers associate with coal or oil elevation not in service close in timed sequence from top to lower elevation -Aux. air dampers associate with oil elevation will modulate as per oil header pressure when oil is being fired. Otherwise modulate with other aux. air dampers -All aux. air dampers will open fully when boiler trip. Fuel air dampers-All fuel air dampers are normally closed. They open 50 second after associate feeder is started, and modulate as per feeder speed.50 second after feeder is removed from service, associate dampers close. They open fully when boiler trip.

Boiler Trip Protections

FSSS protects boiler by tripping out all fuel input under following condition Loss of DC for >2 sec. Less than fireball & loss of AC at any Elev i/s Flame failure Loss of all fuel Both ID fans off Both FD fans off Unit trip relay operated Drum level 2nd high >210 mm Drum level 2nd low<-210mm Furnace pr 2nd high> 175mmWC Furnace pr 2nd low<-175 mmWC Emergency PB trip Re-heater protection Boiler load < 30% .and. Air Flow < 30% EQUIPMENTS TRIPPING WITH MFR ACTUATION UTR trip Both PA Fans trip. All pulverizers trip All Gravimatric feeders trip All Hot Air Gates closes HOTV closes All HONV closes