F.S.S.S.

**********
A. Introduction :
The Furnace Safeguard Supervisory System (FSSS) is designed to assure the
execution of a safe, orderly operating sequence in the start up and shut down of
fuel firing equipment and to prevent errors of omission and commission in
following such a safe operating procedure.
The system provides protection, should there be a malfunction of fuel firing
equipment and associated air systems. The safety features of the system are
designed for protection in most common emergency situations. However the
system cannot supplement the intelligence and the reasonable judgment of the
operator in all the situations.

B. Basic Functions of FSSS :

a.
b.
c.
d.
e.
f.
g.

Prevent any fuel firing unless a satisfactory furnace purge sequence has first
been completed.
Prevent start-up of individual fuel firing equipment unless certain permissive
interlocks have first been satisfied.
Monitor and control the proper component sequence (manual or automatic)
during start-up and shutdown of fuel firing equipment.
Make continued operation of fuel firing equipment subject to certain safety
interlocks remaining satisfied.
Provide components status feedback to the operator.
Provide flame supervision when fuel-firing equipment is in service and
initiate fuel trip upon certain adverse operating conditions.
Provide master fuel trip when certain adverse operating conditions exists.

This FSSS is provided for a natural circulation, HO fired boiler with coal as
primary fuel and light oil (LO) as the start-up fuel.
Heavy oil (HO) is used as fuel for warm up and stabilization .The system provides
three elevations (AB, CD, EF) of high-energy arc (HEA) igniters, oil guns with
atomizing steam in all four corners. Only AB elevation has LO firing guns with
atomizing air. This boiler has six elevations (a, b, c, d, e, f) of coal firing with 24 coal
nozzles. Mill system includes ball and race mill, seal air fan & dampers, primary air
fan, coal feeder, hot air gate, mill inlet / outlet gates hot / cold PA control dampers.

Discriminating scanners are provided for sensing flame of both coal and oil. FSSS has
been designed for energized to open & energized to close philosophy.

C. Boiler Trip Conditions :

1. Both ID fans OFF.
2. Both FD fans OFF.
3.TotalAir flow (secondary + primary) less than 30% of MCR (252 tph).
4. Furnace pressure very high (+150mmwc).
5. Furnace pressure very low (-175mmwc).
6. Drum level very high (+225mm) 10secs delay.
7. Drum level very low (-225mm) 5 secs delay.
8. Loss of all fuel trip. *
9. Loss of reheat protection 10 secs delay. **
10.Loss of 220V dc > 2secs.
11.Loss of unit critical supply (24V dc).
12.Loss of 110V AC > 2secs & loss of fireball. ***
13.Generator class-A trip.
14.Flame failure trip. ****
15.Both emergency push buttons pressed.
*Loss of fuel trip generates when all coal feeders OFF and (all LONV closed or
LOTV closed) and (all HONV closed or HOTV closed). Logic is armed from any oil
nozzle valve not open.
**Loss of Reheat protection generates when any coal feeder proven and Generator
Circuit Breaker open and (any HPBP or LPBP valve < 2%). When turbine is in
service either of the HPCV or HPBP and either of the IPCV or LPBP both valves
should be open > 2% and any feeder proven.
***Loss of 110vAC & loss of fireball happens when all feeders OFF and 110vAC
fails in an oil elevation in service or in a coal elevation with mill ON condition.
****Flame failure logic exists in coal firing condition only. Coal elevation not in
service votes for flame failure. If running coal elevation monitoring fireball scanner
not showing 2/4 flame and is not supported by oil guns then it will also vote. If
any feeder running and all coal elevation vote for flame failure then flame failure
logic acts and boiler trips on flame failure.

D. Purge Permissives :
1. No boiler trip condition persists
2. All HAGs closed.
3. All PA fans OFF.

4. All feeders OFF.

5. All HONV closed.
6. All LONV closed.
7. HOTV closed.
8. LOTV closed.
9. All scanners sensing no flame.
10. Aux air dampers modulating.
11. Air flow > 30% & < 40% MCR.
If all these conditions are fulfilled then PUSH TO PURGE light glows. Press PURGE
START button. 300 secs purge timer starts. Boiler trip circuit resets after purge
complete provided no permissive missed in that period of 300 secs.

E. Selection Of Light Oil / Heavy Oil Firing :

Oil elevation AB is provided with HO / LO firing. Permissives for changeover are
follows:
1. Both pairs of oil gun stopped.
2. All HO/LO nozzle valves closed.
3. HO/LO start permit available.
LOTV LOGICS:
If MFR reset and LO header pressure adequate then LOTV can be operated.
Protections (OR logics):
1. MFT (2/3)
2. Light oil header pressure very low.
3. Atomizing air header pressure very low.
4. NO light oil elevation in start or stop.
LOTV is commanded to close by hardwire circuit on loss of +24v DC.
HOTV LOGICS :
Once MFR resets and all HONV close and HORV open and HO header pressure and
temperature is adequate then HOTV can be open / close.
Protections:
1. MFT.
2. HONV not closed and atomizing steam pr very low and no oil elevation in start / stop
> 2 secs.
3. HONV not closed and HO header pressure very low >2 secs.
4. HO header temp very low and any HONV nozzle valve not closed >2 secs and
HORV valve not open.

LIGHT OIL ELEVATION START:

Select light oil firing. Then check following conditions:
1.
No master fuel trip.
2.
LOTV open
3.
Pulverizer / feeder start permit available. i.e. nozzle tilt horizontal and air flow
>30% and <40% or any feeder ON

PAIR MODE/ELEVATION MODE LOGICS:

For both LO and HO oil guns
are put into service by sequence control logic.
Pair Mode :
Pressing pair start (1-3 or 2-4) PB, provided the above conditions are
satisfied will initiate a 70 secs start time to place the associated light oil guns in service.
Second oil gun gets start command after 15 secs.
Elevation Mode :
When associated coal feeder is in service, oil guns acts under
elevation mode. I.e. all four guns put in or out by single command.
When any of the pair ON PB pressed two things happens a) Elevation start command is
issued for corner 1&3 b) A 40 secs counting period is started to established an elevation
start command for corner 2&4. After 70 secs if nozzle valves are not proven then
unsuccessful elevation start alarm is initiated. This will stop corner 1&3 and after 40
secs stop corner 2&4.
This pair mode & elevation mode logic is same for both HO & LO elevations.

CORNER TRIP LOGIC (HO):

1.
2.
3.
4.
5.
6.

Oil gun not engaged

Lo selected
Ho man isolation valve not open
Local maintenance switch
Steam atomizing man isolation valve not open
Corner start time / scavenge time expired & (corner no flame or HONV not open
or steam valve not open)

Similar logics will be there for light oil guns.

START-UP LOGIC:
STEP 1: Open steam / air atomizing valve

STEP 2: If atomizing valve opens then advance HEA igniter

STEP 3. If HEA rod advanced then open HONV / LONV and spark HEA igniter for 15
secs
STEP 4: If HEA rod retracted and oil valve open in condition and disc scanner shows
Flame then end step sequence.
If flame does not stable within 15 secs from oil valve open then corner trip
Initiated. All the valves of that corner closed and HEA igniter withdrawn.

SHUT-DOWN LOGIC:
STEP 1: Close HONV / LONV
STEP 2: After oil valve closes, open steam / air atomizing valve
STEP 3: After atomizing valve opens, HEA advances & scavenge valve opens. After
advancement of HEA sparks for 15 secs.
STEP 4: After scavenge time of 300 secs atomizing and scavenge valve close.

HORV OPERATION:
Any HONV not close condition is the protection close for HORV. All HONV close is
Open permissive.

F. MILL LOGICS :
Seal Air Fan:
MFT and electrical trip are the protections for this drive. This can be run
when no protection present.
SAF outlet damper can be opened by operator after 40 sec of SAF ON. Seal air to
Pulverizer inlet damper is automatically open when SAF ON and SAF outlet damper open.
It closes by Pulverizer trip command (30secs pulse ).
HAG Logics:
Mill outlet temp >110oC for >=30 secs and MFT are the protection close.
When no protection is present it can be opened and if PA fan OFF then it can be closed also.
Mill Discharge Gate:
This can be opened any time by open command. But it can be closed
when PA fan OFF & PA general shut off damper closed.

Mill Lube Oil Pump :

When one pump running and lube oil pressure low or flow low
occurs then 2nd pump will takes start. When Mill running and running pump for any
reason gets OFF, 2nd pump will take start.
Mill Inlet Gate:
This can be open any time by open command. Off permissive is
Feeder OFF.
PA General Shut Off Damper:
If PA fan ON and mill discharge valve open then it
can be opened. Pa fan OFF closes this damper automatically.

PA Fan Permissives :
1. No MFT
2. PA inlet damper in min position
3. PA general s/o damper closed
4. Ignition permit available *
5. Coal elevation start permit available **
6. PA lube oil system o.k.
7. Cold air damper <5%
8. Mill release available ***
9. No pulverizer trip
10. Seal air system o.k ****
11. PA breaker in service

PA Fan Protections :
1.
2.
3.
4.
5.

Pulverizer trip
2/3 MFT
PA fan electrical trip
PA fan lube oil system failed (lube oil pressure 0.4kgf cm-2< more than 60 secs)
Loss of FD fan trip (for D, E, F elevation)

*Ignition permit available when adjacent oil elevation has 3/4 oil gun in service or
adjacent coal feeder has feeding >50% (18 tph).
**One running FD fan can give start permit to 1st three coal elevation. 2nd FD fan is
required for 4th coal elevation.
Loss of FD fan trip will be generated when one of the two running FD fans trips with
four mills in operation. It will trip the top mill system.

*** Mill release : Available when

PA fan ON or (CAD<5% and PA general shut off damper close
& burner all manual isolation valves open and feeder inlet / outlet gate open and HAG,
CAG open and mill lube oil o.k. and mill gas pressure not low or not very low.

**** Seal air system O.K. will be available when seal air fan ON & SAF o/l damper
open and SA to pulverizer inlet damper open and seal air to hot PA DP >100 mmwc.
Mill Permissives :
1.
2.
3.
4.
5.
6.
7.
8.
9.

Mill release available

PA fan ON >20 secs
PA general s/o damper open
Ignition permit available
Coal elevation start permit available
Pulverizer / feeder start permit available
Pulverizer outlet temp not low (>65degC)
Mill both discharge valves open
Pulverizer breaker in service

Pulverizer / feeder start permit: Burner tilting horizontal and total air flow < 40% or
any feeder running > 53 secs.

Pulv Trip Logics :

1 Pulv ON and (seal air to hot PA DP low (<100mmwc) >70 secs or seal air fan OFF
>60 secs).
2. 2/3 MFT
4. MILL ON and PA fan OFF
5. Mill outlet temp>110 oC and feeder ON
6. Mill release not available
7. Electrical trip
8. Any mill discharge valve not open>3 secs
9. Ignition permit not available and Ignition permit required.
10. Mill gas pressure very low
11. Mill lub oil pressure very low>3 secs or (both lube oil pump OFF or lube oil flow
low)>5 secs.

Feeder Permissives :
1. Coal on belt
2. Feeder in remote
3. Pulverizer / feeder start permit

4. Ignition permit
5. Coal elevation start permit
6. Mill outlet temp not high and not low

Feeder protection:
1.
2.
3.
4.
5.
6.

Ignition permit not available and Ignition permit required

Mill outlet temp high
2/3 MFT
No coal on belt
Feeder discharge plugged
Pulverizer trip

Ignition permit required signal is generated when feeder status (ON / OFF) changes
and it lusts for 3 minutes.
Flame scanner:
We have 5 elevations (AB, BC, CD, DE, EF) of optical scanner,
which can convert flame frequency and amplitude to a current signal. Coal and oil flame
is discriminated by different flame frequency i.e. coal flame frequency 3.5 to 10 Hz and
oil flame frequency 24 to 30 Hz. It thresholds the amplitude and gives flame / no flame
switching signal to FSSS.

PULV AUTO SEQUENCE:

In auto sequence if one step command issued then after
getting desired feedback this step command withdrawn and next step command will be
issued.
START-UP:
STEP-1: start oil elevation if ignition permit is not available
STEP-2: Start seal air fan, open its dampers
STEP-3: Start mill lube oil pumps
STEP-4: Open mill discharge valve
STEP-5: Start PA fan & open general s/o damper
STEP-6: Start Pulverizer
STEP-7: Start feeder
SHUT-DOWN:
STEP-1: Start oil elevation if ignition permit is not available
STEP-2: Run feeder speed to min
STEP-3: Stop feeder
STEP-4: Stop mill
STEP-5: Stop PA fan

STEP-6: Close general s/o damper

STEP-7: Stop seal air fan, close mill discharge gates, stop mill lube oil pumps after 30
minutes.

G. Secondary Air Damper Control:

Coal air damper : A, B, C, D, E, F modulates as a function of coal feeding in auto mode.
Oil air damper : AB, CD, EF Opens 70% when oil gun in service. Else acts as aux air
damper.
Aux air damper : BC, DE Modulates in auto to maintain wind box to furnace DP. DP set
point is a function of boiler load.
Over fire dampers : Modulates in auto as a function of boiler load to prevent SOx, NOx.
When MFT operates, all these dampers are forced to 100% open
and stays there for 5 mins.
Scanner Fan:
Two scanner air fans (AC, DC) are provided. Normally AC fan is
running if it trips or scanner duct to furnace DP low (150mmwc) comes then DC fan
takes start. Scanner fan normally takes suction from FD fan discharge and supply air to
the flame scanner duct. One emergency damper is provided in the suction. In case of
both FD fan OFF, this damper will provide alternate suction.
Mill Fire Fighting Inerting System:
After mill trip, fire fighting inerting command can
be given. It closes Mill inlet / outlet gates, general s/o damper, seal air to mill inlet
damper. After that all the steam valves to mill open for 30 secs. After 30 secs steam
valve closes and cycle stops.