CONTROL & INSTRUMENTATION / FB

CUSTOMER TRAINING PROGRAM

VENUE:
BHEL, HRDC,
TRICHIRAPALLI – 14.

TITLE:
OPERATION, MAINTENANCE & CARE OF BOILERS

LECTURE ON:
OPERATION & MAINTENANCE OF CONTROL &
INSTRUMENTATION

FACULTY:
Mr. R.ANBARASU, Sr. Mgr.-C&I/FB.
PNEUMATIC CONTROL

OPEN/CLOSE POWER CYLINDER

S
AFR

~
AIR LOCK

S
PNEUMATIC CONTROL
REGULATING POWER CYLINDER
POSITION 4-20mA
TRANSMITTER

ZT 4-20mA

AIR FILTER
E/P REGULATOR

I
Positioner

~
P

AFR
AIR SUPPLY

~
AIR LOCK
PNEUMATIC CONTROL
HYDRAULIC CONTROL
ELECTRICAL CONTROL
ELECTRICAL CONTROL
ELECTRICAL CONTROL
ELECTRICAL CONTROL
ELECTRICAL CONTROL
 FURNACE EXPLOSION

- IGNITION OF AN ACCUMULATED COMBUSTIBLE MIXTURE WITHIN THE

COMBINED SPACE OF THE FURNACE OR ASSOCIATED BOILER PASSES,
DUCTS AND FANS THAT CARRY THE FLUE GASES TO THE STACK.

- THE INTENSITY AND MAGNITUNE OF THE EXPLOSION DEPENDS

ON THE RELATIVE QUANTITY OF COMBUSTIBLE FUELS ACCUMULATED
AND THE PROPORTION OF AIR MIXTURE.

-AN INTERRUPTION OF FUEL OR AIR SUPPLY OR IGNITION ENERGY TO

THE BURNERS RESULT IN MOMENTARY LOSS OF FLAMES FOLLOWED BY
RESTORATION AND DELAYED RE-IGNITION OF FUEL ACCUMULATION.

- NEPA 8502 STANDARD NECESSITATES A MINIMUM DEGREE OF

AUTOMATION:
SEC. 5.4 - FURNACE IMPLOSION PROTECTION
6.6.1 - FUEL GAS (INTERLOCK)
7.6.1 - FUEL OIL (INTERLOCK)
 EXPLOSION (FUEL FIRING LOGIC OF BMS)

• EXPLOSION NORMALLY OCCURS DURING START UP AND

SHUTDOWN OF BOILER / ELEVATIONS IN A DISTURBED FURNACE.
(DRAFT)
• NEPA 8502 (EDITION 1995) CHAPTER 2 DEALS WITH EXPLOSION.
• TO AVOID EXPLOSION, MONITORING OF FLOW OF FUEL INSIDE
THE FURNACE IS VERY MUCH ESSENTIAL.
• FLAME FAILURE LOGIC (FFL) OF BMS CHECKS THE
AVAILABILITY OF FLAME IN ANY ELEVATION.
• ON DETECTION OF NO FLAME IN ANY ELEVATION FFL INITIATES
ELEVATION TRIP COMMAND.
• FLAME FAILURE / LOSS OF ALL FUEL/ LOSS OF IGNITION PERMIT
LEAD TO BOILER TRIP.
• BOILER TRIP COMMAND IMMEDIATELY TRIPS FUEL FLOW BY
CLOSING OF MAIN TRIP AND CORNER VALVES, AS WELL AS
TRIPPING OF COAL ELEVATIONS BY CLOSING HOT PRIMARY AIR
GATES.
FURNACE SAFEGUARD SUPERVISORY SYSTEM

DIGITAL GATES
‘ON DELAY’ TIMER
‘OR’ GATE
I/P SIGNAL 1 I/P O/P
2
3 OR O/P

‘OFF DELAY’ TIMER

‘AND’ GATE
I/P SIGNAL 1
I/P O/P
2
3 AND O/P

O/P 1
FLIP FLOP / MEMORY
‘NOT’ GATE S
I/P 1
I/P 2 R O/P 2
I/P
O/P
 FURNACE SAFEGUARD SUPERVISORY SYSTEM

BOILER TRIP PROTECTION

Both F.D. FAN(S) OFF

PB Both I.D. FAN(S) OFF

EMERGENCY TRIP

2/3 FURNACE PRESSURE ‘Very HIGH’ BOILER TRIP

2/3 FURNACE PRESSURE ‘Very LOW’

Y

RESET M.F.R. TO M.F.R

2/3 DRUM LEVEL ‘HIGH’ 10 sec
BOILER TRIP
2/3DRUM LEVEL ‘ LOW’ 5 sec

AIR FLOW < 30

FLAME FAILURE TRIP

LOSS OF FUEL TRIP

 FURNACE SAFEGUARD SUPERVISORY SYSTEM
FURNACE PURGE SUPERVISION

ALL IGNITION VALVES CLOSED PURGE START

ALL HEAVY OIL VALVES CLOSED PURGING

ALL LIGHT OIL VALVES CLOSED PURGE

READY W PURGE COMPLETE AND
FUEL GAS TRIP VALVES CLOSED NO BOILER TRIP

FUEL GAS CORNER N.V. CLOSED

G Y

ALL SCANNERS SHOW NO FLAME RESET M.F.R. TO

ALL AUXILIARY AIR DAMPERS MODULATING

M.F.R
5 MIN
IGNITION TRIP VALVE CLOSED NO BOILER TRIP

LIGHT OIL TRIP VALVE CLOSED

HEAVY OIL TRIP VALVE CLOSED

NO BOILER TRIP
PROGRAMMABLE LOGIC CONTROL
WHAT IS A PLC?
•PLC is short for Programmable Logic Controller. A more common
name would be industrial computer.

•PLC is the heart of most modern factories using automation to increase

the productivity.

•It has a power supply, microprocessor chip, RAM, input / output and
com ports.

•It can sense large number of inputs and control a large number of
outputs all in a matter of milliseconds.

•It uses symbolic programming language.

BASIC PLC OPERATION
INPUT MODULES
Input modules accept a variety of analog or digital signals from various sensors
and convert them to logic signals that can be used by CPU.
OUTPUT MODULES
The output modules convert control instructions from the CPU into signals that can be
used to control various field devices.
CPU
The CPU makes the decision & executes control instructions based on the
program in its memory.
PROGRAMMING DEVICE
Programming device is used to install the instructions that determine what the PLC
has to do in response to specific inputs.
OPERATOR MODULE
The operator interface allows the process information to be displayed and new
parameters to be entered.
 PROCESSOR CONFIGURATION & HARDWARE
REQUIREMENT

• The system shall have dynamic self diagnostic features and indication
for each component failure.
• Redundant central processing units(CPU).
• Redundant I/O system for critical outputs and non-redundant I/O
system for remaining I/Os.
• Engineering console with interface
• Operating console with interface.
• Communication system.
PROGRAMMABLE LOGIC CONTROL
• The CPU shall have capability to meet the following minimum
requirement.
a) Logic functions
b) Timing functions
c) Counter
d) Any other functional capabilities to perform the system
requirement.
• The communication between the sub-system shall be redundant
and with complete error checking.
• In case of redundant processors, the failure of any processor or any
other component shall not affect the operation and the other
processor shall take over the complete operation smoothly
 PROGRAMMABLE LOGIC CONTROL
• On-line replacement of failed processor after rectification shall be
possible , without affecting the operation.
• Redundancy shall be provided for the complete processor system
including CPU, memory, power supply, and communication sub-
system.
• The failure of any single component shall not cause the control
system to be completely inoperative and thus ensuring total
system availability.
• The failure of a processor or any other component shall be
annunciated.The minimum requirements are:
Processor failure
Memory failure
I/O module failure
Communication link failure
Battery voltage level low.
PROGRAMMABLE LOGIC CONTROL

• On failure of a Processor in the system, it shall be possible for the outputs

to be individually freezed, opened or closed.
• On resumption of power supply after a failure, all outputs shall either
open or close as dictated by the process.
• Each processor shall be provided with a separate power supply and
failure of one power supply shall not affect the operation.
• Processor offered shall be suitable to accommodate at least 30% spare
capacity.
International CSA Certified
 BHELMHO Switch
HP Heater

Steam out
Steam in
Electrode
PTFE Cable

Electronic
Cabinet

BHELMHO SWITCH

Stand Pipe 110 / 220V AC

24V DC
Water out Water in

Relay output
Contacts
 BHELMHO Level Switch Applications
Areas of Application in Power and Process Plants
™ De-aerator storage level
™ HP & LP Heater columns
™ Main boiler Drum Level
™ Blow down tank level
™ Main steam header drain
™ Hot and cold reheat drains
™ Turbine Extraction drain
™ Hot well alarms
™ Generator coolant level
™ Turbine casing drain
BHELSCAN BHEL make indigenous
BHELSONIC System

1 595
10
2 544
12
3 505
504
12 14
4 46.95 13
42.5
5 15
6 41.5
7 39.0
30.15 16 17
8
16.0
18
9

LEFT SIDE FRONT SIDE LEFT SIDE

BHELSONIC
BHELSONIC System
•Inadequate cooling capacity
•Inadequate flow of cooling water and /or sample
•Excessive flow of sample
•Leakage’s in cooling & sampling lines
•Analysers starving due to inadequate sample flow
•Chocking of sample lines/ filters
•Chiller : Leakage of refrigerant gas
•Fluctuations in sample flow to analysers
•Quality of cooling waer
•Ignorance in understanding System function.
•Lack of training – steam power engg + instrumentation
•Lack of maintenance
 flow measurement :
Principle of operation of PD flow meter :
PD flow meter : Positive Displacement Meter
Principle of measurement : Displacement of oil by volume.

The oval wheel meter is a volumetric meter.

The measuring element consists of two meshing oval wheels,
driven by the liquid.
Each revolution of the oval wheel displaces a precisely known
volume of liquid through the meter
The number of revolutions is directly proportional to the
measured volume.
Transmission gearing transmits the revolution of oval wheels
to a mechanical register (which counts the flow of volumetric
units).
 Strainer :
Protect the oval wheel meters from solid matter in oil.
Select strainers with 250 microns.

Pulse amplifier :
Generates and amplifies weak pulses proportional to the
volume of oil displaced thro’ the flow meter.

F to I converter :
Converts the pulse generated by the pulse generator into a
linear 4 – 20 mA current signal.
 PD flow meter

Strainer

Oval wheel
Pulse F/I
meter
generator converter
4-20mA to DCS
Turn down ratio :

• Ratio between the minimum and maximum flow rate of

oil through the oil gun.
• Generally for PD flow meter the ratio is 1:10
• For example when maximum flow is 20000kg/hr and
minimum flow is 2000 kg/hr then the ratio is 1:10.
Recommendation for reducing/avoiding PD Flow
Meter problems

The major problem faced in the PDFM :

Improper installation of the meter and improper setting
of the F/I converter.

To avoid Installation problem :

Brief notes with method of installation and Do’s and
Don’ts during installation.
Since the O&M manual does not reach at the appropriate
time.
Contd…..

Alternate meter :
Since mass flow meter is very costly when compared
with the PD flow meter and the problems faced with PD flow
meter are not mainly due to the defect in the equipment but
are installation problems, PD flow meter itself shall be
envisaged for this application with incorporating the
recommended procedure.
AUTO CONTROL SYSTEM
AUTO CONTROL SYSTEM