Professional Documents
Culture Documents
K Karthikeyan
Manager
Controls & Instrumentation
BHEL, Tiruchirappalli
Email : karthi@bheltry.co.in
Boiler C&I
INTRODUCTION
PART I - BOILER
PART 2 - INSTRUMENTATION
PART 3 - CONTROLS
Boiler
Controls & Instrumentation
Functions
Proposal Engineering
Contract Engineering
Product Engineering
Quality Assurance & Control
Field Engineering
Research & Development
Proposal Engineering
Scope of Work
Project Estimate
Offer submission
Offer evaluation by
customer
Award of contract
Proposal Engineering
In summary, the purpose is to draw-up
- Scope of Work
- Project Estimate
of the project.
Deliverables :
- Estimable quantity(BOM)- main and spares
- Datasheets
- Descriptive offers of packages &
- Preliminary design sketches(P&IDs, GA).
Offer evaluation
The offers get evaluated at the customer end.
Award of contract
The offers get evaluated at the customer end.
Contract Engineering
Contract Engineering
Packages
SG integral C&I(Trichy)
Station C&I(PEM or customer)- in case of BTG
or Turnkey
SG integral electricals(Trichy)
Station Electricals(PEM or customer)- in case
of BTG or Turnkey
Contract Engineering
The role involves system level contract
coordination for the boiler C&I area.
Contract Engineering
System Engg. Documents involved :
Piping&Instrumentation Diagrams(P&IDs)
Measurement & control recommendations
Automatic control schemes
Interlock & protection schemes
Product Engineering
Product Engineering
Detailed design of Boiler C&I products &
systems
Digital controls
Analog controls
Electrical systems & cables
Field instruments
Special instruments
Actuators
Product Engineering
Digital Controls
Burner management system.
Soot Blower control system
Analog Controls
Secondary air damper control system.
Auxiliary PRDS control system.
Product Engineering
Electrical systems
Control supply panels
LT Motor control centres
Power distribution panels
Field instruments
Switches & gauges for Pressure,Level &
temperature
Thermocouples
Flow elements
Product Engineering
Special instruments
Product Engineering
Field Engineering
Field Engineering
The role involves
Providing technical support / trouble shooting of
C&I products / system during
- Erection & commissioning stage of project
- Operation after handing over to customer
Review & dispose Commissioning action requests
Review & dispose Contract closing pending issues
Visiting sites to ensure smooth progress of C&I site
activity
Boiler Basics
BOILER CLASSIFICATION
BHEL BOILERS
Power Boilers
Up to 600 MW rating(Coal, oil and gas fired - Subcritical)
Up to 800 MW - Supercritical
Industrial boilers
Up to 450 Tonnes/hour rating
Fertilisers, Petrochemical, Steel & Paper industries
Wide range of fuels- Oil, Gas, BFG, Bagasse, Black liquor.
Natural circulation
Controlled circulation
Once through
Circulation ratio :
Mass rate of water fed to the steam generating tubes to the
mass rate of steam generated.
Natural circulation 6
Controlled circ 4
Once through 1
1. Axial
Impulse type - IGV Control.
Reaction type - Blade pitch Control.
2. Radial
Inlet damper control, Variable speed control;
Variable speed control by two speed motor,
Hydraulic coupling or Variable frequency drive.
Radial Fan
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Axial Reaction
Types :
Volumetric - Rotary and drag link,
AIRHEATER
Types :
Tubular type
Types
H/C ratio
Natural gas 0.3 Fuel oil 0.1 Coal 0.07
Rapid combustion
Boiler Instruments
Boiler measurements
Pressure Flue gas analysis(O2,
Differential pressure CO, SOx, NOx,
Temperature Opacity)
Differential SWAS(Conductivity,
temperature(heat flux) pH, Silica, Dissilved
Flow O2, Hydazine)
Level Image sensing(CCTV)
Vibration (rotating
Sound(steam leak)
device)
Speed (rotating Viscosity (fuel oil)
device) Calorific value
Position
Weight
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Instrumentation
representation- ISA
First letter
Succeeding letters
P-Pressure A- Alarm
T-temperature I- Indicate
F- Flow R- Record
A- Analytical Q- Integrate
C- Control
S- Switch
T- tansmitter
E- Element
P- Pocket
W- Well
Boiler Controls
BOILER CONTROLS
Continuous control :
Objective
Enabling Automatic Operation.
Optimising operating performance.
On-Off control :
Objective
Supervise process operation for safety
Prevent process from entering unsafe condition.
BOILER CONTROLS
Master demand
Feed-water control
Steam-temperature control
Set from unit load demand or main steam header pressure control
Objective :
Fuel is consumed safely, so that the energy is released without risk to plant,
personnel or environment
FT PT FT
A f(x)
P I
A T
SP SP
P I LO SELECT HI SELECT P I
Fuel CONTROL AIR CONTROL
A T A T
To "dry" coal.
Air flow to mill and mill outlet temperature are regulated using Hot
air damper and cold air damper respectively
Feedwater control
Objective :
Feedwater control
S T E AM D R UM F E E D WAT E R
P R E S S UR E FLOW T E MP E R AT UR E L E VE L P R E S S UR E F L O W T E MP E R AT UR E
PT FT TE LT PT FT TE
D
K
T A
M/A C O NT R O L
S TAT IO N
Typical s ingle-drive control s ys tem. F or s implicity, redundant
trans mitters have not been s hown on this typical control drawing. f(x) F INAL
S ee F igure 4A for ANS I/IS A-S 5.1-1984 format. C O NT R O L
D E VIC E
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Objective:
To maintain a constant steam temperature at turbine inlet despite large load
swings .
Basic methods :
DESUPERHEATING (ATTEMPERATION)
Fine spray of comparatively cool water droplets into the vapour to reduce
steam temperature.
Two types of dampers Fuel air dampers & Auxiliary air dampers
Above 30% unit load, BMS closes elevations of auxiliary dampers that are
not required for elevations of fuel currently in service
High windbox to furnace differential pressure opens all the secondary air
dampers
SH DESH outlet temp. error positions the spray control valve such
as to regulate the MS temperature within allowable limits.
Scope :
Sequence control of starting and protection &
interlocking of boiler auxiliaries
FD fans
ID fans
PA fans
Airheaters
Dampers
Valves
Tangential Windbox
SECONDARY AIR
SECONDARY AIR
FSSS
FUNCTIONS OF FSSS
F - FURNACE
S - SAFEGUARD
S - SUPERVISORY
S - -SYSTEM
START UP
LOW LOAD OPERATION
SHUT DOWN.
FSSS
FSSS
UNIT LOGIC
ELEVATION LOGIC
CORNER LOGIC
FSSS
FSSS
BOILER TRIP COMMAND RESULTS IN
1. ALL PULVERIZERS
2. ALL FEEDERS
3. ALL OIL GUNS
4. ALL IGNITORS
IT CLOSES
1. IGNITOR
2. LIGHT OIL TRIP VALVES
3. HEAVY OIL TRIP VALVES
FSSS
PULVERIZER STARTING PROCEDURE
START
PULVERIZER ON FEEDBACK
OPEN HOT AIR GATE
WAIT TILL PULVERIZER COMES TO TEMPERATURE
( 140F )
START FEEDER ( AT MINIMUM FEEDER SPEED )
COAL FLOW INDICATOR OR PULVERIZER AMPERE (
( WITH IN 5 SECONDS )
FIFTY SECONDS
FEEDER SPEED RELEASED TO AUTOMATIC CONTROL
FUEL AIR DAMPER OPENED
FUEL AIR DAMPER MODULATED TO AUTOMATIC
CONTROL.
FSSS
PULVERIZER START REQUIREMENTS
FSSS
CONDITIONS ( LOCAL ) TO BE SATISFIED TO START
RESPECTIVE PULVERIZER
FSSS
OR
FSSS
WILL
AND
FSSS
FEEDER CONTROL
FSSS
BOILER TRIP
FSSS
FSSS
FSSS
ARRANGEMENT OF SYSTEM
LOGIC CABINET
CONSOLE INSERT
SECONDARY AIR DAMPER PANEL
MILL PANEL
FIELD EQUIPMENTS
CUSTOMER SUPPLIED INTERFACE
EQUIPMENT.