Case study- Unit 1 PA fan B BPC 0 due to feedback problem but unit got saved.

Observations - As per trend it is clearly visible that

7:56:10.186- PA B BPC 0 command
7:57:05.742- PA header pressure 465 without any action.
7:57:16. - No action yet and header pressure 465
7:57:20.910- First action running fan BPC increasing started .
7:57:49.062- BPC increased from 32 to 46 and header has already increased to 580.

At same time HAG of Mill E has been closed by operator, result in PA header increase up to
640 mmwc.

7:57:57.066- Between above time and this time BPC and current is constant indicating no
operator action. From this time onwards again BPC has been increased till 7:58:07.554 resulting
PA header to increase to 733 mmwc.

Cursor 1 - Time till which no command given or no action has been taken.

Cursor 2 - Time at which HAG E has been closed.

Observations

1.As PA header was running 700 mmwc from p/s shift so when BPC of PAF B closed the
header pressure stopped at 465 mmwc and did not go below it.

2. PA fan B no load current was 32 indicating slight partial load.

3. Minimum PA air flow was 160 at lowest point in 4 mills.

4.  Prior to earlier tripping PA header was running 650 mmwc. So fall in header pressure was
very steep and unit got tripped.

Logic modification done -

Logic for 0 command to BPC on off feedback was delayed by 1 s  . This saved the unit 3 times
in similar situations. When this also failed a condition for current less than 10 amp was added in
and gate. 

From above occurrences it is very clear that unit may survive on one PA fan if other fan BPC
gets closed.
Further reliability improvement considering what was not done in this case or in case of BPC
malfunction due to failure of above logic, or any other cause or possibility.

Stop command to closing BPC.

Idea 1- Alarm and SOE. Too many alarms. Especially unit 1 and only 3 alarm visible window for
fast response.

Idea 2 - oil gun simultaneous command to all 4 corners. Elevation mode to avoid unit outage.

Idea 3 - in case a 0 command is executed to a PA fan BPC the other fan BPC increment
command by 10 to 15 %. 

New scenario-

In case PA fan trips current will directly become 0 and BPC will close. There are chances that
unit can be saved if considering following possibilities.

We maintain header pressure 730 and 50 t in all mills may just save us from tripping .

On tripping of PA fan discharge gate closes in auto besides BPC closing.

Oil gun comes in elevation mode to save the boiler even if turbine trips.

4 th mill cut out and HAG close.

Running fan BPC 10% increment command.

Some PA fans BPC are running in range of 20 to 30 %. This will give less time and unload the
fan in shorter time in comparison to PA fans running in range 40 %.