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Boiler Controls & Instrumentation

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

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Boiler
Controls & Instrumentation

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Boiler C&I -Functions

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Broad engineering activities

Control systems engineering


Instrumentation engineering
Electrical systems engineering
New product development

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Functions

Proposal Engineering
Contract Engineering
Product Engineering
Quality Assurance & Control
Field Engineering
Research & Development

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Proposal Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation
Proposal Engineering

Scope of Work
Project Estimate
Offer submission
Offer evaluation by
customer
Award of contract

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

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).

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation
Scope of Work
Arrived based on a broad specification prepared by
the customer/consultant.

Individual system scope identified gets recompiled


into a project scope of work .

Project scope document includes scope of work ,


terminal points & exclusions

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation
Scope of Work
The typical scope covered in Boiler C&I discipline
include
Furnace safeguard Supervisory system
Secondary Air Damper control system
Soot blower control system
Boiler area field instruments
Associated cable & accessories.
Electricals(MCC, elevator etc.)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Offer evaluation
The offers get evaluated at the customer end.

Customer awards the contract on a technically


qualified bid with the lowest price.

The award of contract is indicated by a Letter


of Intent received from the customer.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Award of contract
The offers get evaluated at the customer end.

Customer awards the contract on a technically


qualified bid with the lowest price.

The award of contract is indicated by a Letter


of Intent received from the customer.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Contract Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Contract Engineering
The role involves system level contract
coordination for the boiler C&I area.

Applicable PGMA List


Sub Delivery check list.
Boiler Contract Regular activity(BCR) schedule
00 PG list(erection documents).
Applicable O&M documents.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Contract Engineering
System Engg. Documents involved :
Piping&Instrumentation Diagrams(P&IDs)
Measurement & control recommendations
Automatic control schemes
Interlock & protection schemes

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
P & I Diagram- Air & flue gas (portion)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
Instrument schedule steam & water (sample)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Product Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Product Engineering
Detailed design of Boiler C&I products &
systems
Digital controls
Analog controls
Electrical systems & cables
Field instruments
Special instruments
Actuators

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Product Engineering
Digital Controls
Burner management system.
Soot Blower control system

Analog Controls
Secondary air damper control system.
Auxiliary PRDS control system.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Product Engineering
Special instruments

Flame scanner system


Acoustic steam leak detection system.
Electronic water level indicator.
Closed circuit television system.
Vibration monitoring system.
Flue gas analysers.
Steam and water analysers.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Product Engineering

Electrical and C & I engineering design


Release of indents for C & I sub-delivery items.
Evaluation of technical offers for bought-out
items
Technical Delivery Conditions (TDC)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Quality Control & Assurance

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Quality Control & Assurance


The role involves preparation/review of
following activity w.r.t C&I products & systems

Prepare Standard Quality Plans (SQP)


Prepare Contract Quality Plans (CQP)
Review/Approve Vendor Quality Plans (VQP)
Issue Reference Quality Plans (RQP)
Prepare Inspection Check Lists (ICL)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Quality Control & Assurance

Performing inspection at vendor works for CI


products & systems - bought-out items
Review & dispose Site Action Requests on CI
products & systems

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Field Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I Boiler Controls & Instrumentation

Research & Development

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Research & Development

In-house developed C&I systems & products

Microprocessor based Gravimetric coal feeder


controls - BHELFEED
Microcontroller based Flame moniotirng
system - BHELSCAN
Acoustic steam leak detection system
BHELSONIC
Electronic water level Indicator system-
BHELVISION
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I

Boiler Basics

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

BOILER CLASSIFICATION

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

BHEL BOILERS

Power Boilers
Up to 600 MW rating(Coal, oil and gas fired - Subcritical)
Up to 800 MW - Supercritical

Nuclear steam generators


Up to 235 MW rating

Industrial boilers
Up to 450 Tonnes/hour rating
Fertilisers, Petrochemical, Steel & Paper industries
Wide range of fuels- Oil, Gas, BFG, Bagasse, Black liquor.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Bharat Heavy Electricals Limited - Tiruchirappalli


Schematic of a boiler
Boiler C&I

UTILITY BOILERS - ESSENTIAL COMPONENTS

Furnace & Circulation system


Superheaters
Reheaters
Economiser
Airheaters
Fans
Pulverisers
Raw coal feeders
Fuel firing system
Sootblowers

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
CIRCULATION SYSTEMS

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

Bharat Heavy Electricals Limited - Tiruchirappalli


BOILER CIRCULATION SYSTEMS

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
Fans

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.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Radial Fan
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I

Axial Reaction

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Boiler C&I

RADIAL FANS - SPEED CONTROL

- Flow proportional to Speed


- Flow proportional to (Impeller Dia) 3

- Head proportional to (Speed) 2


- Head proportional to (Impeller Dia) 2

Hence Variation in speed alters the performance

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FANS IN BOILER - SCOPE

Primary air fans - Dries & transports Pulverised coal

Forced draft fans - Supplies Combustion air

Induced draft fans - Sucks Flue gas out of furnace

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

MILL - GRINDS COAL

Slow speed mills (Tube mills - 15 to 25 RPM)

Medium speed mills (Bowl mill, Ball and race mill

etc.- 50 to 100 RPM)

High speed mills (hammer mills directly coupled to

motor - 750 to 1000 RPM)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

RAW COAL FEEDERS

Scope : CONVEY RAW COAL TO MILL

Types :
Volumetric - Rotary and drag link,

Gravimetric Endless belt type

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

AIRHEATER

Heat recovery equipment


Extract heat from Flue gas to heat primary & secy. Air

Types :

Regenerative type ( Rotating drive )

Tubular type

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
SOOTBLOWERS

Remove ash & slag from pressure part tubes

Types

Long retractable sootblowers - traverse & rotary motors


Half retractable sootblowers- traverse & rotary motors
Rotary blowers - rotary motor
Wall blowers - traverse & rotary motors
Furnace temperature probe - Used during boiler start up

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
FUELS & COMBUSTION

Fuels : Coal Oil Gas

H/C ratio
Natural gas 0.3 Fuel oil 0.1 Coal 0.07

Calorific value (kcal/kg )


Gas 10000 Oil 8000
Bituminous coal 3000-3500 Lignite 2500

Coal burning methods


"On grate" In suspension" Fluidised bed

Three 'T's of combustion


Time
Temperature and
Turbulence.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
FUELS & COMBUSTION

Rapid combustion

Short period of time


High temperature &
Very turbulent flame .

Less turbulence and longer burning produces fewer nitrous oxide.

In some cases combustion is delayed or staged intentionally to obtain


fewer nitrous oxide or to obtain desired flame characteristics.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Boiler Instruments

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Boiler Controls

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

BOILER CONTROLS

Auto control system

Boiler Auxiliaries interlocks & protection system

Furnace safeguard supervisory system (FSSS)

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Auto control system.

Master demand

Combustion and draft control

Feed-water control

Steam-temperature control

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
Master demand

'Master demand' controls the boiler operation.

Set from unit load demand or main steam header pressure control

Master demand sets burners firing at a rate required for steam


production and corresponding air flow demand

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
Combustion control

Fuel flow control

Air Flow Control

Coal mill control

Objective :

Fuel is consumed at a rate that exactly matches the Steam demand.

Fuel is consumed safely, so that the energy is released without risk to plant,
personnel or environment

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Combustion control Air Fuel/Cross Limiting


STEAM
Fuel FLOW HEADER PRESSURE AIR FLOW

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

f(x) Air Feed


Fuel Feed
AIR DAMPER
Bharat Heavy Electricals Limited - Tiruchirappalli 67
Boiler C&I

Mill air flow and temperature control

Mill uses primary air -

For transporting coal from mill to furnace.

To "dry" coal.

Air flow to mill and mill outlet temperature are regulated using Hot
air damper and cold air damper respectively

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Feedwater control

Objective :

To supply enough water to the boiler to match the evaporation rate.

Water level in the drum indicates amount of water in boiler

Actual Steam Flow - Used to determine required feedwater during


transient conditions when level may not be accurate.

Difference between Actual steam flow and Actual Feedwater Flow is


added to the level error to form the Feedwater demand.

Feedwater demand drives the feed control station to adjust feedwater


sa as to maintain the drum level to normal value.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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

f(x) f(x) f(x) f(x)


X X P R E S S UR E X
C O MP E N S AT IO N T E MP E R AT UR E
P R E S S UR E AND C O ND E NS AT IO N
T E MP E R AT UR E
C O MP E NS AT IO N D A S E T P O INT
K

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

Steam temperature control

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.

BURNER TILT POSITIONING

Raise/Lower the Fireball in the furnace by tilting burners upwards or


downwards.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Steam temperature control

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Secondary Air Damper Control

Two types of dampers Fuel air dampers & Auxiliary air dampers

Maintains proper windbox air flow distribution

0 to 30 % unit load, all auxiliary dampers modulated to maintain windbox to


furnace differential pressure

Above 30% unit load, BMS closes elevations of auxiliary dampers that are
not required for elevations of fuel currently in service

Fuel air dampers are positioned on an elevation basis as a function of the


corresponding coal feeder speed

High windbox to furnace differential pressure opens all the secondary air
dampers

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Steam temperature control

Cascade control used for Spray de-superheating loop

MS temperature error establishes the set point for SH DESH


outlet temp.

SH DESH outlet temp. error positions the spray control valve such
as to regulate the MS temperature within allowable limits.

Burner tilt responds to the lower of SH or RH outlet temp.

Spray control responds to the higher of SH or RH outlet temp.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

BOILER AUXILIARIES INTERLOCKS AND PROTECTION SYSTEM

Scope :
Sequence control of starting and protection &
interlocking of boiler auxiliaries
FD fans
ID fans
PA fans
Airheaters
Dampers
Valves

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FURNACE SAFEGUARD SUPERVISORY SYSTEM


( FSSS )

This system takes care of interlocks required for


starting, supervising the operating and safe shut
down of the equipments connected with fuel firing
system.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Tangential Windbox

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
FURNACE PLAN CORNER DESIGNATION

SECONDARY AIR
SECONDARY AIR

FRONT WATER WALL

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
Fireball Tangential Firing

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

CAUSES OF FURNACE EXPLOSIONS


An interruption of
Fuel or
Air supply or
Ignition energy
to the burners, sufficient to result in momentary loss of flames,
followed by restoration and delayed re-ignition of an accumulation.

Fuel leakage into an idle furnace and the ignition of the


accumulation by a spark or other source of ignition.
Repeated unsuccessful attempts to light-off without appropriate
purging, resulting in the accumulation of an explosive mixture.
The accumulation of an explosive mixture of fuel and air as a result
of loss of flame or incomplete combustion at one or more burners in
the presence of other burners operating normally or during lighting
of additional burners.
The accumulation of an explosive mixture of fuel and air as a result
of a complete furnace flameout and the ignition of the accumulation
by a spark or other ignition source, such as could occur where
attempting to light a burner(s).
Purging with an airflow that is too high, which stirs up combustibles
smoldering in hoppers.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

CAUSES OF FURNACE IMPLOSIONS

A mal-operation of the equipment regulating the boiler gas flow,


including air supply and flue gas removal, resulting in furnace
exposure to excessive induced draft fan head assembly.

The rapid decay of furnace gas temperatures and pressure resulting


from either a rapid reduction in fuel input or a master fuel trip.

A combination of the two conditions indicated in a, b above has


resulted in the most severe furnace implosion incidents.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

FUNCTIONS OF FSSS

1. FURNACE PURGE SUPERVISION


2. SECONDARY AIR DAMPER MODULATION AND ON-OFF CONTROL
AND SUPERVISION
3. IGNITOR ON-OFF CONTROL AND SUPERVISION
4. LIGHT OIL ON-OFF CONTROL AND SUPERVISION
5. HEAVY OIL ON-OFF CONTROL AND SUPERVISION
6. PULVERIZER AND FEEDER ON-OFF CONTROL AND SUPERVISION
7. FLAME SCANNER INTELLIGENCE AND CHECKING
8. BOILER TRIP PROTECTION.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
FSSS

F - FURNACE
S - SAFEGUARD
S - SUPERVISORY
S - -SYSTEM

FSSS ENSURES SAFE FURNACE OPERATING CONDITIONS DURING

START UP
LOW LOAD OPERATION
SHUT DOWN.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

SOME OF THE PRECAUTIONARY MEASURES TO ACHIEVE SAFE


AND RELIABLE OPERATION

FURNACE SHOULD BE PURGED BEFORE LIGHT UP


ADEQUATE IGNITION ENERGY TO EACH BURNER
ADEQUATE AIR SUPPLY TO EACH BURNER TO AVOID
FLAME OUT
OPTIMUM FURNACE PRESSURE
CORRECT AIR TO FUEL RATIO

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

FUNCTIONAL DIVISION OF LOGICS

UNIT LOGIC

ELEVATION LOGIC

CORNER LOGIC

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

TYPICAL CONDITIONS FOR FURNACE PURGE:

Heavy fuel oil trip valve All pulverisers off.


closed. All feeders off.
Heavy fuel oil nozzle valves Pulveriser outlet gates
closed. closed.
Light fuel oil trip valve All hot air gates closed.
closed. All cold air dampers not
Light fuel oil nozzle valves greater than 5 open.
closed. Both PA fans off.
Flame scanners on each No boiler trip existing.
elevation indicate no flame.
All auxiliary air dampers
Air flow greater than 30% modulating.
and less than 40%

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

BOILER TRIP COMMAND IS INITIATED BY

LOW OR HIGH DRUM WATER LEVEL


BOTH I.D OR F.D ARE OFF
LOW OR HIGH FURNACE PRESSURE
REHEATER PROTECTION TRIP
TURBINE
LOSS OF ALL FUEL TRIP
LOSS OF UNIT D.C POWER
LESS THAN FIRE BALL AND LOSS OF AC AT
ANY ELEVATION
MANUAL TRIP
UNIT FLAME FAILURE TRIP
INSUFFICIENT PRIMARY AIR

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS
BOILER TRIP COMMAND RESULTS IN

STOPPAGE OF ALL FUEL INPUTS BY TRIPPING

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

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Scanner Fan logic

Scanner duct to furnace DP when low


initiates a Scanner air fan -A run command
If DP value remains low for more than five
seconds, scanner air fan -B run command is
issued.
If DP condition is low even after 10 seconds
Loss Of Scanner Cooling Air alarm is
generated

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Seal Air Fan Control

When either Primary Air Fan is on, seal air fan


A is automatically placed in service.
If either Primary Air Fan is on & Seal Air
Header/Cold Air Duct DP is low, the seal air
fan is auto started.
When both seal air fans are on and the Seal
Air Header/Cold Air Duct DP is not low,either
seal air fan can be stopped manually.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

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.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS
PULVERIZER START REQUIREMENTS

A IGNITION ENERGY AVAILABLE

B. ADEQUATE PRIMARY AIR

C. D.C POWER AVAILABLE

D. LOCAL PULVERIZER CONDITION SATISFACTORY

E. IF NO OTHER FEEDER IS WORKING FUEL AND AIR


NOZZLE TILTS PLACED IN HORIZONDAL
CONDITION.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS
CONDITIONS ( LOCAL ) TO BE SATISFIED TO START
RESPECTIVE PULVERIZER

A. DISCHARGE VALVE OPEN

B. SEAL AIR VALVE OPEN

C. COLD AIR DAMPER OPEN

D. PULVERIZER DAMPER OUTLET LESS THAN 200F

E. FEEDER INLET GATE OPEN

F. TRAMP IRON HOPPER VALVE OPEN.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

PULVERIZER IGNITION ENERGY AVAILABLE

A MINIMUM OF 3 OF THE 4 LIGHT OIL OR HEAVY OIL


NOZZLE VALVE OF THE ELEVATION JUST ABOVE OR
BELOW, ARE OPEN

OR

BOILER LOADING IS GREATER THAN 30% AND


PULVERIZER JUST ABOVE OR BELOW IS IN SERVICE AT
GREATER THAN 50% LOADING.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

MILL OUTLET TEMPERATURE CONTROL

HIGH PULVERIZER OUTLET TEMPERATURE (ABOVE 200F )

WILL

OPEN COLD AIR DAMPER

AND

CLOSE HOT AIR GATE.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

FEEDER CONTROL

A. FEEDER RUNS AT MINIMUM SPEED UNTIL


INITIATING CONDITION IS CORRECTED, AT
WHICH TIME THE FEEDER WILL BE RETURNED
TO CONTROL.
A. PULVERIZER BOWL DIFFERENTIAL HIGH.
B. PULVERIZER AMPS. ABOVE MAXIMUM SET POINT.

B. LOSS OF COAL FLOW AND LOW PULVERIZER


CURRENT WILL TRIP THE FEEDER, OPEN COLD AIR
DAMPER AND CLOSE HOT AIR GATE.
AFTER CORRECTIVE ACTION THE HOT AIR GATE IS
OPENED AND FEEDER IS RESTARTED.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

CONDITIONS FOR A PULVERIZER TRIP

PULVERIZER DISCHARGE VALVE NOT OPEN

LOSS OF UNIT DC POWER (FOR MORE THAN 2 SECONDS)

PULVERIZER IGNITION PERMIT NOT SATISFIED AND SUPPORT


IGNITION IS REQUIRED.

BOILER TRIP

PRIMARY AIR FAN TRIP

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

PULVERIZER SHUT DOWN SEQUENCE

START ASSOCIATED OIL ELEVATION


REDUCE FEEDER SPEED TO MINIMUM
CLOSE HOT AIR GATE
PULVERIZER OUTLET TEMPERATURE IS 120F
STOP FEEDER
WAIT FOR 2 MINUTES
STOP PULVERIZER
FURNACE STABILIZES
ASSOCIATED OIL LEVEL SHUT DOWN.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

PULVERIZER SHUT DOWN

START ASSOCIATED OIL ELEVATION


REDUCE FEEDER SPEED TO MINIMUM
CLOSE HOT AIR GATE
PULVERIZER TEMPERATURE IS 120F
STOP FEEDER
TWO MINUTES
STOP PULVERIZER
FURNACE STABILIZES
SHUT OFF ASSOCIATED OIL ELEVATION.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

FSSS

ARRANGEMENT OF SYSTEM

FSSS - MAJOR PARTS

LOGIC CABINET
CONSOLE INSERT
SECONDARY AIR DAMPER PANEL
MILL PANEL
FIELD EQUIPMENTS
CUSTOMER SUPPLIED INTERFACE
EQUIPMENT.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I

Oil gun start sequence


HEA Advances
Atomising valve opens
Corner oil valve opens
HEA sparks
Flame scanner picks up flame
HEA retracts
Corner valve closes if flame is not sensed.

Bharat Heavy Electricals Limited - Tiruchirappalli


Boiler C&I
FSSS Oil gun start up timing sequence
THANK YOU

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