-DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institute affiliated to VTU, Belagavi – 590018, Approved by AICTE & ISO 9001:2015 Certified)
Accredited by National Assessment & Accreditation Council (NAAC) with ‘A’ grade

Submitted by

NISHANT SAGAR

1DS18EI033
ON
BOILER INTERLOCK AND PROTECTION OF 330 MW UNIT

DEPARTMENT OF ELECTRONICS & INSTRUMENTATION ENGINEERING

(Accredited By NBA)

DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institute Affiliated to VTU, Belagavi)

Shavige Malleshwara Hills, Kumaraswamy Layout, Bengaluru - 560078

PAGE-01
 ABOUT THE COMPANY

Adani Group, is an Indian multinational conglomerate company

headquartered in Ahmedabad, Gujarat, India. It was founded by
Gautam Adani in 1988 as a commodity trading business, with the
flagship company Adani Enterprises Limited (previously Adani Exports
Limited). Gautam Adani is the chairman. The Group's diverse businesses
include energy, resources, logistics, agribusiness, real estate, financial

services, defence and aerospace. It is India's largest port developer and

operator with ten ports and terminals including Mundra Port, its
largest.

The Adani Group commenced as a commodity trading firm in 1988 and

diversified into the import and export of multi-basket commodities.
With a capital of 5 lakhs, the company was established as a partnership
firm with the flagship company, Adani Enterprises Limited, previously
Adani Exports Limited.
2
• Title
• Acknowledgement
• Content
• Abstract
• Report
• Conclusion
• Bibliography
I would like to express my special thanks of gratitude to the
HR "Mr. Amit Kumar Pandey" for their able guidance and
support in completing my project.

I would also like to extend my gratitude to my senior

colleagues and associates for providing me with all the
facility and prior knowledge that was required.

Also, I would like to mention the support system and

consideration of my parents who have always been there in
my life. And, last but not the least, I express my gratitude to
my friends who have always been there with my
side. Without them I could never had completed this task.
The main objective of the paper is to demonstrate
all the protections and interlocks available for
Boiler
management, and show how boiler is protected
from abnormal conditions using intelligent logics in
a Thermal Power Plant. The existing interlocks are
working with general logic system. Unnecessary
tripping of Boiler leads to loss of Generation, long
maintenance and high cost.
Boiler Interlocks includes:
 APH trip.
 ID fan trip.
 PA fan trip.
 Runback
 One APH Trip
 One ID fan will trip

a) If ID fan A & B are running then ID fan A will trip on APH A trip &
ID fan B will trip on APH B trip.
b) If ID fan B & C are running then ID fan B will trip on tripping of APH
A & ID fan C will trip on tripping of APH B
c) If ID fan A & C are running then ID fan A will trip on tripping of
APH A & ID fan C will trip on tripping of APHB.

 Flue gas Inlet damper will close.

 PA Inlet and Outlet damper will close.
 Secondary Air Inlet and Outlet damper will close and Interconnection
damper will also close.
 One ID Fan Trip
▪ One FD fan will trip on tripping of one ID fan.
a) If ID fan A & B are running then FD fan A will trip on ID fan A trip
& FD fan B will trip on ID fan B.
b) If ID fan B & C are running then FD fan A will trip on tripping of ID
fan B & FD fan B will trip on tripping of ID fan C.
c) If ID fan A & C are running then FD fan A will trip on tripping of ID
fan A & FD fan B will trip on tripping of ID fan C.
 Inlet and Outlet damper, IGV will close, Scoop will be in minimum.
 AOP will start in auto.
 Tripping of FD Fan will close its discharge damper and blade pitch will
come in minimum position.
 One PA Fan Trip
 In five mill operation, two mill & with four mill operation
one out of E,D & C will trip on priority basis.

Mill running. Trip

A,B,F,D,E,C E,D,C
A,B,F,D,E E,D
A,B,F,D,C D,C
A,B,F,C,E E,C
A,B,F,D,E E,D

• Discharge damper will close and blade pitch will be minimum

 Runback
 FSSS receives 2 RB operation from CCS System
(1) Runback-1 (ID/FD, BFP Trip.)
 Tripping of Mill E,D,C on priority basis with 6Sec. delay.
(2) Runback-2 (PA Fan trip.)
 Tripping of Mill E,D,C on priority basis with 3Sec. delay.

 Runback system input the oil to ensure stable burner i.e. Only inputting
one elevation oil guns.
FSSS:- Furnace Safeguard Supervision System

Functions:-
 MFT & Reason
 OFT
 Oil leakage Experiment.
 Supply Oil valve & Oil return valve control
 Flame test & control of cooling fan.
 Ignition approval of oil unit and coal unit.
 Seal Air fan control
 Runback
Protections are Security measures taken to
ensure the safety of equipment .
Boiler protections includes:
1. MFT (Master Fuel Trip)
2. Purging.
3. ID fan
4. FD fan
5. PA fan
6. Seal air fan
7. Coal Mill
8. Coal Feeder
9. Input Coal Permit.
10. Input oil permit.
MFT is boiler trip relay which cuts all fuel
source and primary air going to furnace.
Trip logics Set point
All FD fan stop 1Sec. Delay
All ID fan stop 1Sec. Delay
All PA fan stop
Furnace press.HH ( 2 out of 3 ) Delay 2 sec. + 1700 Pa
Furnace press.LL ( 2 out of 3 ) Delay 2 sec. - 2500 pa
Drum LVL HH ( 2 out of 3 ) Delay 5 sec. 250 mm
Drum LVL LL ( 2 out of 3 ) Delay 10 sec. 250 mm
Total Air flow < 30% Delay 10 sec 300 TPH
Furnace flame loss
Boiler Fuel loss
All APH Stop Delay 1 min.
Manual MFT
MFT After reset 3 ignition failure / Delay 10 min ignition
All Scanner air fan stop Delay 10 sec.
Scanner air fan HDR pr.LL ( 2 out of 3 )

Reheater protection
 Reheater Protection
(a) After Synchronization
 Turbine trip and HP BYPASS<30% and Boiler load>30% with any
mill in service.
(b) Before Latch
 With any Mill in service HP BYPASS <30%
(c) After Latch
 With any Mill in service HP BYPASS <5%

 All Fuel Lost

 All Mill and Feeder stopped and supply oil valve or all oil valve closed
condition with 5 Sec Delay.
 Furnace Flame Lost
(a) Any Mill running for 60 Sec. then on tripping of any Mill (10+2 Sec.)or no
coal elevation flame and No Oil input.
(b) Critical flame loss 9 out of 20 flame scanner loss within 10 Sec.
 OFT
 Manual OFT
 MFT
 Supply Oil Pr. LL 5Sec Delay
 Supply Oil valve closed 5Sec Delay
 All Oil Corner Valve Closed 2Sec Delay
 Return Oil valve closed 5Sec Delay

OFT Reset
 Purge end with 2Sec Delay
 Supply oil Valve open
PURGING is removing of combustible gases and
unburnt from the furnace through air.

 Purge conditions
(1) All PA Fan stop condition.
(2) Supply oil valve closed condition.
(3) All Corner valve Closed.
(4) All Mill stop.
(5) All Coal Feeder stop.
(6) Any ID/FD running.
(7) Total Air flow > 30%.
(8) Furnace Pr. Normal. (No High and Low Switch act)
(9) Drum Level normal.
(10) No MFT.
(11) Both APH running.
(12) All Scanner no flame.
(13) No Leak test.
(14) Aux. Air damper at purge site. (Average opening>50%)
 Input Coal Permit
 Secondary air temp suitable (average of APH O/L SA Temp>177˚C)
 Air>30%
 No MFT
 PA fan running
 Seal air Pr. Not low.
 Primary air Pr. Suitable(>5kpa)

Input Oil Permit

 Boiler supply oil Pr. Not low
 Flame CAF Pr. Suitable
 Compress air Pr. Not Low<0.6Mpa
 Air>30%
 Supply oil temp not low
 Purging end.
 Coal Mill
 Fast Stop
(1) Mill Lube oil STN. Not meet. (any of following)
(a) High speed LOP trip.
(b) Oil temp>70 ˚C
(c) Oil Pr.<0.1Mpa
(2) Mill running and Coal Feeder Stop.(30+270 Sec.)
(3) Coal Feeder running and no material for 60Sec. Then after 270Sec
Fast stop.
(4) Loading Oil pump stop.
(5) Roller fall and Pr.<1.5Mpa delay of 20Sec.
(6) PA Flow<0.6Q(42 TPH for 5Sec.)
(7) Mill outlet Temp. 95˚C (2 out of 3 Average of 1&2, 3&4, 5&6)
 Urgent Stop
(1) Urgent stop button
(2) PA flow <0.5Q (37 TPH)
(3) Mill outlet temp>100˚C
(4) Seal air to primary air Dp (below<1Kpa)
(5) Mill in stop and feeder running.
(6) Temp HH
(a) Motor DE & NDE Alarm-80˚C Trip-90˚C
(b) Thrust Brg. Temp Alarm-60˚C Trip-70˚C
(c) Winding Temp(2/3) Alarm-110˚C Trip-130˚C
(7) FSSS
(8) MFT
(9) Mill Running and 2 MDV closed.
(10) All PA Fan stop 5Sec.
(11) Coal level no flame.
 Mill Fast stop will close Hot air gate on 5Sec delay.
 Mill urgent stop will lead to
 Feeder trip,
 Hot air gate will close.
 On 5 Sec Cold air gate will close.
 After 2Sec all MDV will close.
 Coal Feeder
 MFT
 Urgent stop
 Coal feeder O/L damper close (2Sec.)
 No material on belt (120Sec.)
 Feeder O/L plugged (5Sec.)
 Coal feeder condition not meet.
1. Coal feeder belt MTR. Fail.
2. Coal feeder belt track alarm.
3. Coal feeder over temp.
 Inlet and Outlet gate will close, Feeder command will come minimum
position.
 ID Fan
Trip Condition Switch Alarm Trip Remark
HC Inlet Temp -------- 65 ˚C 75˚C
HC Outlet Temp -------- 88 ˚C 95 ˚C
HC Bearing Inlet Temp -------- 95 ˚C 105˚C
HC Bearing outlet Temp -------- 95 ˚C 105˚C
Thrust Brg. Temp 2 of 3 75 ˚C 80 ˚C
Non Thrust Brg. Temp 2 of 3 75 ˚C 80 ˚C
Winding Temp 2 of 6 110 ˚C 130 ˚C
MTR. DE/NDE Temp -------- 70 ˚C 85 ˚C
IDF Thurst. Brg. Vib. 4.6 7.1 mm/s
IDF N.Thr. Brg. Vib. 4.6 7.1 mm/s
HC Oil Pr. 0.12Mpa 0.1Mpa 2Sec Delay
Lube Oil Pr. 0.08Mpa 0.05Mpa 3Sec Delay
Furnace Pr. LLL -3250Pa
Side APH Trip
 FD Fan
Trip Condition Switch Alarm Trip Remark
Thrust Brg. Temp 2 of 3 90 ˚C 95 ˚C
Non Thrust Brg. Temp 2 of 3 90 ˚C 95 ˚C
Winding Temp 2 of 6 110 ˚C 130 ˚C

FDF Thr.& N.Thr Hr. Brg. Vib. --------- 4.6 7.1 mm/s

FDF Thr.& N.Thr. Vr. Brg. Vib. --------- 70 ˚C 85 ˚C

MTR. DE Temp --------- 70 ˚C 85 ˚C

MTR. NDE Temp

Furnace Pr. HHH Trip at 3250 Pa After MFT

Oil Pr. LL 2Sec Delay

Oil Tank Level L 5Sec Delay
Side ID Fan Trip

Stalling 60Sec Delay

 PA Fan
Trip Condition Switch Alarm Trip Remark
Thrust Brg. Temp 2 of 3 90 ˚C 95 ˚C
Non Thrust Brg. Temp 2 of 3 90 ˚C 95 ˚C
Winding Temp 2 of 6 110 ˚C 130 ˚C
PAF Thr.Hr. Brg. Vib. --------- 4.6 8.5 mm/s
PAF Thr.Vr. Brg. Vib. --------- 4.6 8.5 mm/s
PAF N.Thr.Hr. Brg. Vib. --------- 4.6 8.5 mm/s
PAF N.Thr.Vr. Brg. Vib. --------- 4.6 8.5 mm/s
Lube Oil Outlet Pr. LL 3Sec Delay
MTR. DE & NDE Temp -------- 70 ˚C 85 ˚C
Oil Tank Level L 5Sec Delay
Stalling --------- 60Sec Delay
 Seal Air Fan
 Temp HH
(1) Brg. Temp. Alarm-70˚C Trip-75˚C
(2) Winding Temp. Alarm-110˚C Trip-130˚C
 PA fan stop for 15Sec.
 Seal air fan control failure/Fault.
 Stand by Seal Air Fan will pick up on Seal air Pr. Low (12kpa) for 5Sec
and on stopping of running fan with 2sec delay.

Scanner air fan

 Stand by Scanner Air Fan will start with Pr. Low switch for 2Sec.OR
Running Fan stop for 2Sec.
Conclusion
 Boiler interlock protection is the safety provision
provided to ensure the safety of the boiler operation.
The boiler would trip incase any of the safety interlock
parameter goes in the unsafe limit. Some of the
interlocks for solid fuel fired boiler are boiler trip
incase of steam drum low level, ID fan trips,
Instrument air pressure fails. For oil and gas fired
boiler the interlocks are burner will not fire until flame
is not sensed, failure of instrument air pressure, Drum
level low, FD fan failure, fuel gas pressure low, oil
pressure low.
Bibliography
 Sam G. Dukelow, “The Control of Boilers”
 D. F. Dyer , “Boiler safety improvement for safety
controls utilizing flow measurement for input” WIT
Transactions on Engineering Sciences, Vol 59, pp441-
445, 2008
 Sangeeth G.S, Praveen Marathur, “Efficiency
Improvement of Boilers” International Research
Journal of Engineering and Technology (IRJET),
Volume: 02 Issue: 05, pp 265-268, Aug-2015