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ID/FD FAN LOGIC SYSTEM

24 May 2012

PMI Revision 00

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PURGE PERMISSIVES
All HFO nozzle valves closed All pulverisers OFF All feeders OFF No MFT condition present All scanners senses no flame All Auxiliary Air dampers modulating Both PA fans OFF All Mill HAGs closed Air flow more than 30% and less than 50% HFO trip valve is closed
24 May 2012

TO FSSS

Wind box to furnace DP is adequate
PMI Revision 00

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Both FD fans OFF Both ID fans OFF. Inadequate water wall circulation for more than 5 seconds. Loss of Reheat Protection for greater than 10 seconds. All BFPs tripped. Drum level very high for more than 10 seconds (2/3 logic) Drum level very low for more than 10 seconds (2/3 logic) Furnace pressure very high (2/3 logic) Furnace pressure very low (2/3 logic) Loss of all fuel. All feeders OFF and loss of AC Supply to the elevation in service. Unit flame failure. Loss of Unit Critical Power for more than 2 seconds Both Secondary APHs OFF. Loss of 220 V DC Supply for more than 2 seconds. Air flow less than 30% and boiler load not greater than 30%. Manual Emergency trip.
24 May 2012 PMI Revision 00 3

Both FD fans OFF

Both ID fans OFF Inadequate water wall circulation for more than 5 seconds
Loss of Reheat Protection for greater than 10 seconds All BFPs tripped Drum level very high for more than 10 seconds (2/3 logic) Drum level very low for more than 10 seconds (2/3 logic) Furnace pressure very high (2/3 logic) Furnace pressure very low (2/3 logic) Loss of all fuel All feeders OFF and loss of AC Supply to the elevation in service Unit flame failure Loss of Unit Critical Power for more than 2 seconds Both Secondary APHs OFF Loss of 220 V DC Supply for more than 2 seconds Manual Emergency PB trip Air flow less than 30% and boiler load not greater than 30%
24 May 2012 PMI Revision 00 4

MFT RELAY

 Loss of furnace pressure control and balanced draft • Protection Check:  Simulate the signals from ID Fans Electrical Control Circuit 24 May 2012 PMI Revision 00 5 . ALL ID FANS OFF • Logic:  Always armed  Both ID Fans ‘OFF Contact’ sensed by MFT panels • Purpose:  Anticipatory protection to prevent furnace pressurization • Protection Delay:  0 sec – INSTANT.• Arming: 1.

• Arming: 2. • Purpose: • Protection Delay: • Protection Check:  Simulate the signals from FD Fans Electrical Switchgear 24 May 2012 PMI Revision 00 6 . ALL FD FANS OFF • Logic:  Always armed  Both FD Fans ‘OFF Contact’ sensed by MFT panels  Anticipatory protection to prevent reducing firing condition  Loss of total air flow control and balanced draft  0 sec – INSTANT.

PA Fans)  0 sec – INSTANT. simulate status of manual valve (done by C&I). LOSS OF ALL FUEL • Logic:  Any HFO/LFO nozzle valve NOT closed  All LFO cut off AND All HFO cut off AND All Feeders OFF  Initiation of a mandatory purge cycle to restore furnace • Purpose: Backup protection to trip remaining equipment (eg. then give sequence start command to that corner 24 May 2012 PMI Revision 00 7 .• Arming: 3. • Protection Check:  Keep oil manual isolating valves in any one elevation any one corner (done by OPN).

• Protection Check:  Simulate ‘feeder proven’ status without any oil in service PMI Revision 00 8 24 May 2012 . Elevation A voted no flame means –  (AA 3/4 fireball scanners sense no flame AND AB 3/4 fireball scanners sense no flame AND AB 2/4 oil guns not proven in service) OR Feeder A Not Proven for 2 sec  Stop firing under unstable flame fireball conditions • Protection Delay:  0 sec – INSTANT. FLAME FAILURE • Logic:  Any Feeder Proven for 2 sec  All Elevations A to K voted NO Flame  Eg.• Arming: 4.

FURNACE PRESSURE VERY HIGH • Arming: • Logic:  Always armed • Purpose:  2 out of 3 pressure switches sense furnace pressure very high > +150 mmwc  To stop fuel firing under explosive tendency of furnace  0 sec – INSTANT.  Prevent furnace structural distortion • Protection Delay: • Protection Check:  Simulate from protection instrument. or by actual pressurization if agreed by Operation Head.5. 24 May 2012 PMI Revision 00 9 .

6. or by actual depressurization if agreed by Operation Head. • Protection Delay: • Protection Check:  Simulate from protection instrument. FURNACE PRESSURE VERY LOW • Arming: • Logic:  Always armed • Purpose:  2 out of 3 pressure switches sense furnace pressure very low < -175 mmwc  To stop fuel firing under implosive tendency of furnace  Prevent furnace structural distortion  0 sec – INSTANT. 24 May 2012 PMI Revision 00 10 .

DRUM LEVEL VERY HIGH • Arming: • Logic: • Purpose: Always armed  2 out of 3 logic derived from hydrastep-left-1. • Protection Delay: • Protection Check:  Actual (increase feed water flow slowly until level reaches trip limit). 24 May 2012 PMI Revision 00 11 . hydrastepright-1 and drum level transmitter > 250 mm  To prevent water carry over to superheater headers and subsequently to turbine  10 sec.7.

DRUM LEVEL VERY LOW • Arming: • Logic:  Always armed • Purpose:  2 out of 3 logic derived from hydrastep-left-2. 24 May 2012 PMI Revision 00 12 . • Protection Delay: • Protection Check:  Actual (decrease feed water flow slowly until level reaches trip limit).8. hydrastepright-2 and drum level transmitter < -375 mm  To prevent waterwall tubes starvation  To prevent BCW pumps starvation  5 sec.

ALL BFP OFF • Logic:  Always armed  Both TDBFPs sensed ‘Not Working’ AND MDBFP sensed OFF • Purpose: • Protection Delay:  10 sec.  Anticipatory protection for Drum Level Very Low  To prevent economizer tubes starvation • Protection Check:  Simulate OFF contact of all BFP from BFP control panel 24 May 2012 PMI Revision 00 13 .• Arming: 9.

ALL SAH OFF • Logic:  Always armed  Both Secondary Air Heaters: electric motor OFF AND air motor OFF  Preventing poor furnace combustion due to low secondary air temperature  Preventing flue gas damper isolation in all air heaters  5 sec. • Purpose: • Protection Delay:  Actual.• Arming: 10. 24 May 2012 • Protection Check: PMI Revision 00 14 .

 Preventing DNB (departure from nucleate boiling) • Protection Check:  Equalizing DP transmitters to simulate DP low.11. 24 May 2012 PMI Revision 00 15 .68 ksc • Purpose:  Preventing damage to waterwall tubes due to insufficient cooling flow/circulation • Protection Delay:  5 sec. WATERWALL CIRCULATION INCORRECT • Arming: • Logic:  Boiler ON  All BCW OFF (OR) 2/3 running BCW DP < 0.

24 May 2012 PMI Revision 00 16 .

• Protection Check:  Actual.12. 24 May 2012 PMI Revision 00 17 . TOTAL AIR FLOW < 30% • Arming: • Logic:  Always armed • Purpose:  Total Air Flow (Primary Air + Secondary Air) < 30% of full load air flow (30% of 1800 Tph = 540 Tph)  Ensuring absolute minimum required quantity of air flow even during startup  Preventing localized accumulation of unburnt oil during startup • Protection Delay:  0 sec .INSTANT.

24 May 2012 PMI Revision 00 18 .

24 May 2012 PMI Revision 00 19 .13. • Protection Check:  Actual. REHEATER PROTECTION • Arming: • Logic:  HP bypass AND LP bypass charged for the first time > 2%  Generator Circuit Breaker Open AND (HP bypass OR LP bypass Fail to Open) OR Reheater Inlet (HP) OR Outlet Path (IP/LP) Blocked  Ensuring absolute minimum required quantity of air flow even during startup  Preventing localized accumulation of unburnt oil during startup • Purpose: • Protection Delay:  10 sec.

24 May 2012 PMI Revision 00 20 .

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• Protection Check:  By 24V breaker simulation in MFT panel. the processors cannot execute any logic. LOSS OF 24V DC • Logic:  Always armed  If 24V supply to any 2 MFT panels is lost.• Arming: 14. 24 May 2012 PMI Revision 00 22 . it will initiate a hardwired MFT protection through 220V contactor circuit. • Purpose:  If 24V fails. leading to unsafe condition • Protection Delay:  0 sec – INSTANT.

• Protection Delay:  2 sec. • Purpose:  If 220V fails. 24 May 2012 PMI Revision 00 23 . LOSS OF 220V DC • Logic:  Always armed  If 220V supply to any 2 MFT panels is lost.• Arming: 15. backup protection for 24V failure will be unavailable. • Protection Check:  By 220V breaker in MFT panel. it will initiate a soft MFT protection through processor logic.

 Failure of processors leads to unsafe condition  0 sec . it will initiate MFT protection. or if any 2 MFT processors go into frozen output state. 24 May 2012 PMI Revision 00 24 .  This ensures that at least 2 processors are in healthy condition at any point of time when boiler is in service.INSTANT. • Protection Delay: • Protection Check:  By actually creating frozen output state in processors. 2/3 PROCESSORS FAIL/FROZEN • Arming: • Logic:  Always armed • Purpose:  If any 2 MFT processors out of 3 go into failed state.17.

they will initiate MFT protection  This ensures that at least 2 processors are communicating properly at any point of time when boiler is in service. • Purpose: • Protection Delay: • Protection Check:  By actually isolating network connections of the processors.  Failure of communication leads to malfunction of protection circuit  0 sec . 24 May 2012 PMI Revision 00 25 .17.INSTANT. 2/3 PROCESSORS COMMN FAIL •Arming: • Logic:  Always armed  If any 2 MFT processors out of 3 stop communicating with the Ethernet network (redundant net-A and net-B).

Furnace excessive Clinkering. • Purpose: • Protection Delay: • Protection Check:  By actually operating push buttons/through PC. HFO oil leakage during startup. Boiler Tube Leakage.• Arming: 18. EMERGENCY TRIP • Logic:  Always armed  If both Desk Emergency Push Buttons pressed together (OR) If both Backup Panel Push Buttons pressed together (OR) If MFT is confirmed through popup from any workstation PC  This facility allows the operation desk engineer to directly trip the boiler in case of any operational emergency eg. .INSTANT. 24 May 2012 PMI Revision 00 26  0 sec . turbine related emergencies etc.

• Purpose: • Protection Delay:  0 sec – INSTANT (5 min delay in arming circuit)  By simulation at source.POST-TRIP PURGE FANS TRIP • Arming: • Logic:  Boiler not firing fuel for 5 min (MFT may or may not be reset)  If furnace pressure very high > 150 mmwc OR very low < -175 mmwc (AND) Air Flow > 30% THEN TRIP all ID Fans and FD Fans  This protection safeguards furnace against furnace pressure very high OR very low when boiler is NOT firing. • Protection Check: 24 May 2012 PMI Revision 00 27 .

 This interlock achieves the fastest possible load reduction. and requires NO intervention of desk engineer • Purpose: • Protection Delay:  Varies from 1 sec to 1 min according to type of auxiliary  Simulated at initiating point. PMI Revision 00 28 • Protection Check: 24 May 2012 . PA. FD. BFP) trips and standby is not available. until 4 running mills from bottom remain. ID. unit load is automatically reduced according to the new capability  Mills are tripped one by one starting from top running mill.RUNBACK – GRADED MILL TRIP • Arming: • Logic:  More than 4 mills in service  If any major auxiliary (eg. at 2 sec delay.

24 May 2012 PMI Revision 00 29 .

THANK YOU … QUESTIONS ? 24 May 2012 PMI Revision 00 30 .

Bearing temperature not high. Lube oil pressure adequate. • • • Discharge damper fully closed. FD FAN START PERMISSIVES • Blade pitch position minimum. Control oil pressure adequate. One ID Fan running AND other FD fan not running. OR Both ID Fan running 24 May 2012 PMI Revision 00 31 .P&I OF BOILER AUXILLARIES A. • • • Oil tank level normal.

TRIPS • Fan bearing temperature very high • Post purge furnace pressure very high/ very low • Outlet damper fail to open in set time (3 min) • No ID fan running or one ID fan and one FD fan already in service. 24 May 2012 PMI Revision 00 32 .

not high Discharge damper closed. Lube oil tank level adequate No MFT & Cold air damper closed At least one FD fan is running and PAPH A/B in service & respective air inlet/ outlet dampers are open 24 May 2012 PMI Revision 00 33 .PA FAN START PERMISSIVES • • • • • • • • • Blade pitch minimum Lube oil pressure adequate Control oil pressure adequate Bearing temp.

• Discharge damper fails to open. 24 May 2012 PMI Revision 00 34 .TRIPS • Fan bearing temperature very high. • Trip from FSSS (MFT).

coupling OK. • Bearing temperature not high.ID FAN START PERMISSIVES • Hyd. • Oil temp. coupling Scoop position minimum. and oil level in Hyd. • Lube oil pressure adequate. • Other ID fan not running or Any FD fan running. • Both inlet and outlet dampers closed. 24 May 2012 PMI Revision 00 35 . • Inlet guide vane position minimum.

• Lube oil pressure very low. very high.TRIP CONDITION • Fan/Motor bearing temperature very high. very high • Hydraulic coupling oil temp. 24 May 2012 PMI Revision 00 36 .) • Hydraulic coupling bearing temp. • Discharge dampers/ suction damper fail to open within specified time (3 min. • Post purge furnace pressure Hi/Low from FSSS.

SGWC PUMPS: (CC Pumps) PERMISSIVES • Discharge valve 1 open. • Discharge valve 2 open. • Pump cavity – suction manifold differential temp. 24 May 2012 PMI Revision 00 37 . • Motor cavity temp. • Motor cooling water flow adequate. not high. not high.

high (60 deg. 24 May 2012 PMI Revision 00 38 . • Electrical protection trip/ EPB pressed.TRIPS • Any of the discharge valves not fully open. • Motor cavity temp. C) for more than 5 Sec.

Run back operation • Tripping of PA Fan or FD Fan • PA header pressure low/very low • Sequential tripping of Mills/Feeders 24 May 2012 PMI Revision 00 39 .

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