Boiler Trip Condition

Boiler trip (MFT) conditions are as follows:

(a) Boiler Trip PB operated
(b) All BFP Stop
(c) All Flame Loss
(d) All Fuel Loss
(e) Unstable Combustion
(f) Reheater Protection
(g) Both FDF Stop
(h) Both IDF Stop
(i) Feed Water Flow Very Low (<330 TPH)
(j) Boiler Outlet Main Steam Pressure Very High (>284.2 kg/cm2)
(k) Furnace Press Very High(>400mmWC)
(l) Furnace Press Very Low (<-400mmWC)
(m) W/W Outlet Temperature Very High
(n) 1RY SH Outlet Steam Temperature Very High
(o) Boiler Metal temperature Very High
(p) Air Flow Very Low (<644.8 TPH)
(q) WSDT Level Very High (>14.4 mtr)
(r) Turbine Trip With Condenser Vacuum Very Low
(s) Boiler Closed Loop Control System (Station DCS) Failure
(t) Burner Management System (BMS) Failure
a): Boiler trip push button operated:
This is for emergency trip by the operator at the occurrence of a fatal incident. There are two
no’s of push button (NTPC scope) located in operator’s console. Either of the button shall be
pressed to trip the boiler.

b): All BFP stop:

The boiler trip due to stop of all boiler feed pump (BFP) is to prevent the damage to water wall
tube due to extreme unbalance of water/fuel ratio.

 ALL FLAME LOSS MFT-------WHEN:

AT LEAST ONE COAL FEEDER IS IN SERVICE

AND MFT

FURNACE A FLAME LOSS (IN ALL 8 ELEV)

OR

FURNACE B FLAME LOSS (IN ALL 8 ELEV)

 ELEVATTION FLAME LOSS OCCURS WHEN

(COAL FLAME LOSS IN 3 OUT OF 4 CORNERS OF THE SAME ELEVATION)

AND

(FLAME LOSS IN 2 OUT 4 CORNERSON ADJACENT OIL ELEVATIONS DUE TO FLAME LOST OR BURNER
OPEN FEEDBACK LOST)

OR

RESPECTIVE COAL FEEDER TRIPPED

d): All fuel loss:

MFT is provided from ‘All Fuel Loss’ condition when all coal feeder/mill stopped and all oil
burner valves closed after usage of any of the burners. This trip condition is armed , once
generator is synchronized i..e 52 G closed.

e): Unstable combustion:

In case, fuel pressure or atomizing air pressure drop below the limit of burner safe use, boiler
trip (MFT) is initiated judging the unstable combustion.
However, in the coal firing boiler, MFT is not initiated even if this condition is established during
the coal burner operation judging that the furnace combustion is maintained by coal burner
combustion.

The detection of unstable fuel supply for oil burner by the following conditions will cause a boiler
Trip:
1. Oil burner header pressure low low (<5.2 kg/cm2) (2 out of 3 with 3 sec. delay) while any
oil burner is in service and any coal burner is not in service.
2. Atomizing air pressure low low (<3kg/cm2) (2out of 3 value with 3 sec. delay) While any
oil burner is in service and any coal burner is not in service.
f): Reheater protection:

Boiler trip is initiated to protect the reheater against burning in the case that excessive boiler
heat input is charged withsteam flow in the reheater tube is stopped or blocked.

Below are the following condition for steam blocked condition:

TG MSV or main CV closed & both HP Bypass CV closed

OR
TG ISV closed or IP CV closed & both LP Bypass CV closed

If in steam block condition, total fuel flow reaches more than 30% MCR for more than 10
seconds.
OR
If In steam block condition, total fuel flow reaches more than 20% MCR for more than 20
seconds

Reheater protection will be activated.

g): Both FD Fan stop:

The stopping of both FDFs requires immediate stoppage of combustion and blocking of the fuel
charge. Therefore, MFT is initiated.

h): Both ID Fan stop:

Especially the stoppage of both IDFs may cause the accumulation of unburned fuel in the
furnace or cause the furnace explosion. Therefore, MFT is initiated.

i): Feed Water flow low low:

This logic is provided to prevent the damage of water wall against burning.
If the feed water flow becomes low low (<330 TPH for 30 seconds or more) when boiler is being
fired, a boiler trip is initiated to prevent damage of the water wall tube.

j): Boiler outlet main steam pressure very high:

If the main steam pressure of boiler outlet becomes high high (>284.2 kg/cm2) for three (3)
seconds, a boiler trip is initiated to prevent the over-pressurizing of the boiler pressure part.
If in any side (left or right) steam pressure becomes high high MFT shall be initiated.

k): Furnace pressure very high:

The MFT from “Furnace Draft High High” is provided to minimize the damage due to abnormal
combustion such as furnace explosion.
 If the furnace pressure becomes high high (>400mmWC) for three (3) seconds when the boiler
is being fired, a boiler trip is initiated.
The Forced Draft Fans continue in service if they are still operating after the boiler trip.
Separate set of transmitters for control/monitoring & MFT are not used to eliminate any
confusion of monitoring /control and MFT in case of difference in reading due to chocking of the
impulse pipe or transmitters malfunction or any other reasons.

l): Furnace pressure very low:

The boiler trip from “Furnace Draft Low Low” is provided to minimize the damage due to
abnormally low furnace pressure. The main cause of abrupt and abnormal drop of furnace
pressure is the malfunction of furnace draft control system. Also, abnormal combustion may
result with the abnormal furnace pressure drop.
If the furnace draft becomes low low (<- 400mmWC) for three (3) seconds or more when the
boiler is being fired, a boiler trip is initiated.
The Induced Draft Fans continue in service if they are still operating after the boiler trip.
Separate set of transmitters for control/monitoring & MFT are not used to eliminate any
confusion of monitoring /control and MFT in case of difference in reading due to chocking of the
impulse pipe or transmitters malfunction or any other reasons.

m): Water Wall outlet temperature very high:

To prevent the overheating of the pressure part due to abnormal, 3 no. s of w/w outlet
temperature very high signals generated in BOP-C&I DCS based on function of WSDT pressure
will be hardwired to BPS for boiler tripping.

n): Primary SH outlet temperature very high:

Purpose of this protection is to prevent overheating of the pressure part due to mal-operation
(open) of the WDC valves and so on.
The temperature set point is derived from function of WSDT pressure.as per ASME allowable
stress table.

o): Boiler metal temperature very high:

Feed water flow and Fuel flow are normally controlled in Auto mode, so that the balance
between Feed Water and Fuel Flow is maintained by cross limit function thereby maintaining
boiler tube metal temperature under safe limits to prevent the overheating of the Boiler tubes
leading to Boiler tube metal temperature High High condition.
As per ASME, the allowable stress of the provided tube is reduced by 20% and correspond to
reduced stress the allowable temperature is calculated. The calculated allowable temperature is
set as alarm point. The allowable stress and allowable temperature is calculated as per ASME
SEC‐II,
Part‐D. MFT is initiated if temperature value increase 30 deg C above the alarm value with 60
sec. delay.
For example:
Furnace intermediate header inlet metal temperature is calculated as follows:
555 deg C based on high Alarm setting (525 deg C) + 30 deg C (from 2 out of 100 metal
temperature)
For 2ry SH outlet metal temperature:
679 deg C based on high Alarm setting (649 deg C) + 30 deg C (from 2 out of 136 metal
temperature)
p): Air flow very low:
When Air flow becomes low low (<644.8 TPH) for three (3) seconds MFT is initiated to prevent
fuel rich condition in the furnace.

q): WSDT level high high:

When WSDT (Water Separator Drain Tank) level reaches to high high (>14.4 mtr)limit for a
continuous period of 30 second, MFT is initiated in order to avoid water induction into the
turbine.

r): Turbine trip with condenser vacuum low low:

“MFT by Turbine trip” is not necessary for the boiler which has the function of Boiler Isolated
Operation. However, if turbine bypass system is not available because of condenser protection
MFT is initiated.
Since the boiler cannot be in operation (Boiler island operation) under such condition, it is
recommended to trip the boiler by this interlock before RH protection is activated in view of
prevention of unnecessary safety valve actuation.

s): Boiler closed loop control system failure:

The boiler safety operation, monitoring and protective interlock for relative process cannot be
possible in case of BOP-C&I DCS controller failure. Since under such condition, it is dangerous
to operate the plant, MFT is initiated.
MFT will be initiated under failure of following Functional Group (FG) of BOP-C&I DCS,
Secondary Air (A/B), Steam & Water (A/B), Primary Air (A/B).

t): Burner Management (BMS) system failure:

Since the boiler safety operation and monitoring cannot be possible in case of SG-DCS
controller failure, MFT is initiated.
FG of any running elevation (oil or coal) fails then MFT is initiated.

NOTE:
 No MFT has been considered on Scanner air Fan Failure.
There is DC scanner air Fan which is supposed to take care in case of AC scanner fan
failure or in case of Scanner air to furnace DP low .Hence, there is no MFT considered.
 Wet to dry changeover occurs between 20% to 30% load. From 30% till 20% of boiler
load, no feed pump changeover operation is permitted to ensure steady feed flow supply
as per demand. Since MDBFP capacity is 30% as informed by NTPC/ABFPL, runback is
not provided in case of TDBFP trip under ( 1 MDBFP + 1 TDBFP) operation catering
80% TMCR load.
 MFT relays will be de-energised to trip.
 Hardwire 2V3 voting logic shall made by BPS relay logic.
 Noted. Both MFT PB NC contacts shall be connected in series. Each MFT PB pressed
contacts will be connected to each BPS DI from BPS relay panel. The boiler EPB
pressed signal shall be generated from MFT PB PRESSED auxiliary relay contact &
same shall be connected to BPS logic as MFT cause.