ID/FD FAN LOGIC SYSTEM

April 21, 2020 PMI Revision 00 1

 PURGE PERMISSIVES
All HFO nozzle valves closed
All pulverisers OFF
All feeders OFF

No MFT condition present

All scanners senses no flame

TO
All Auxiliary Air dampers modulating
FSSS
Both PA fans OFF

All Mill HAGs closed

Air flow more than 30% and less than 50%

HFO trip valve is closed

Wind box to furnace DP is

April 21, 2020
adequate
PMI Revision 00 2
• Both FD fans OFF
• Both ID fans OFF.
• Inadequate water wall circulation for more than 5 seconds.
• Loss of Reheat Protection for greater than 10 seconds.
• All BFPs tripped.
• Drum level very high for more than 10 seconds (2/3 logic)
• Drum level very low for more than 10 seconds (2/3 logic)
• Furnace pressure very high (2/3 logic)
• Furnace pressure very low (2/3 logic)
• Loss of all fuel.
• All feeders OFF and loss of AC Supply to the elevation in service.
• Unit flame failure.
• Loss of Unit Critical Power for more than 2 seconds
• Both Secondary APHs OFF.
• Loss of 220 V DC Supply for more than 2 seconds.
• Air flow less than 30% and boiler load not greater than 30%.
• Manual Emergency trip.
April 21, 2020 PMI Revision 00 3
 Both FD fans OFF
Both ID fans OFF
Inadequate water wall circulation for more than 5 seconds
Loss of Reheat Protection for greater than 10 seconds
All BFPs tripped
Drum level very high for more than 10 seconds (2/3 logic)
Drum level very low for more than 10 seconds (2/3 logic)
Furnace pressure very high (2/3 logic)
Furnace pressure very low (2/3 logic) MFT
Loss of all fuel RELAY
All feeders OFF and loss of AC Supply to the elevation in service
Unit flame failure
Loss of Unit Critical Power for more than 2 seconds
Both Secondary APHs OFF
Loss of 220 V DC Supply for more than 2 seconds
Manual Emergency PB trip
April 21, 2020 PMI Revision 00 4
Air flow less than 30% and boiler load not greater than 30%
 1. ALL ID FANS OFF
• Arming:
 Always armed
• Logic:
 Both ID Fans ‘OFF Contact’ sensed by MFT panels
• Purpose:
 Anticipatory protection to prevent furnace pressurization
 Loss of furnace pressure control and balanced draft
• Protection Delay:
 0 sec – INSTANT.
• Protection Check:
 Simulate the signals from ID Fans Electrical Control Circuit

April 21, 2020 PMI Revision 00 5

 2. ALL FD FANS OFF
• Arming:
 Always armed
• Logic:
 Both FD Fans ‘OFF Contact’ sensed by MFT panels
• Purpose:
 Anticipatory protection to prevent reducing firing condition
 Loss of total air flow control and balanced draft
• Protection Delay:
 0 sec – INSTANT.
• Protection Check:
 Simulate the signals from FD Fans Electrical Switchgear

April 21, 2020 PMI Revision 00 6

 3. LOSS OF ALL FUEL
• Arming:
 Any HFO/LFO nozzle valve NOT closed
• Logic:
 All LFO cut off AND All HFO cut off AND All Feeders OFF
 Initiation of a mandatory purge cycle to restore furnace

• Purpose:
Backup protection to trip remaining equipment (eg. PA Fans)
 0 sec – INSTANT.

• Protection Check:
 Keep oil manual isolating valves in any one elevation any one corner (done by OPN), simulate
status of manual valve (done by C&I), then give sequence start command to that corner

April 21, 2020 PMI Revision 00 7

 4. FLAME FAILURE
• Arming:
 Any Feeder Proven for 2 sec
• Logic:
 All Elevations A to K voted NO Flame
 Eg. Elevation A voted no flame means –
 (AA 3/4 fireball scanners sense no flame AND AB 3/4 fireball scanners sense no flame AND AB 2/4 oil guns not proven in service) OR
Feeder A Not Proven for 2 sec

 Stop firing under unstable flame fireball conditions

• Protection Delay:
 0 sec – INSTANT.
• Protection Check:
 Simulate ‘feeder proven’ status without any oil in service

April 21, 2020 PMI Revision 00 8

 5. FURNACE PRESSURE VERY HIGH
• Arming:
 Always armed
• Logic:
 2 out of 3 pressure switches sense furnace pressure very high > +150 mmwc

• Purpose:
 To stop fuel firing under explosive tendency of furnace
 Prevent furnace structural distortion
• Protection Delay:
 0 sec – INSTANT.
• Protection Check:
 Simulate from protection instrument, or by actual
pressurization if agreed by Operation Head.

April 21, 2020 PMI Revision 00 9

 6. FURNACE PRESSURE VERY LOW
• Arming:
 Always armed
• Logic:
 2 out of 3 pressure switches sense furnace pressure very low < -175 mmwc

• Purpose:
 To stop fuel firing under implosive tendency of furnace
 Prevent furnace structural distortion
• Protection Delay:
 0 sec – INSTANT.
• Protection Check:
 Simulate from protection instrument, or by actual
depressurization if agreed by Operation Head.

April 21, 2020 PMI Revision 00 10

 7. DRUM LEVEL VERY HIGH
• Arming:
Always armed
• Logic:
 2 out of 3 logic derived from hydrastep-left-1, hydrastep-right-1 and drum level transmitter >
250 mm

• Purpose:
 To prevent water carry over to superheater headers and subsequently to turbine

• Protection Delay:
 10 sec.
• Protection Check:
 Actual (increase feed water flow slowly until level
reaches trip limit).

April 21, 2020 PMI Revision 00 11

 8. DRUM LEVEL VERY LOW
• Arming:
 Always armed
• Logic:
 2 out of 3 logic derived from hydrastep-left-2, hydrastep-right-2 and drum level transmitter <
-375 mm

• Purpose:
 To prevent waterwall tubes starvation
 To prevent BCW pumps starvation
• Protection Delay:
 5 sec.
• Protection Check:
 Actual (decrease feed water flow slowly until level
reaches trip limit).

April 21, 2020 PMI Revision 00 12

 9. ALL BFP OFF
• Arming:
 Always armed
• Logic:
 Both TDBFPs sensed ‘Not Working’ AND MDBFP sensed OFF

• Purpose:
 Anticipatory protection for Drum Level Very Low
 To prevent economizer tubes starvation
• Protection Delay:
 10 sec.
• Protection Check:
 Simulate OFF contact of all BFP from BFP control panel

April 21, 2020 PMI Revision 00 13

 10. ALL SAH OFF
• Arming:
 Always armed
• Logic:
 Both Secondary Air Heaters: electric motor OFF AND air motor OFF

• Purpose:
 Preventing poor furnace combustion due to low secondary air temperature

 Preventing flue gas damper isolation in all air heaters

• Protection Delay:
 5 sec.
• Protection Check:
 Actual.

April 21, 2020 PMI Revision 00 14

 11. WATERWALL CIRCULATION INCORRECT
• Arming:
 Boiler ON
• Logic:
 All BCW OFF (OR) 2/3 running BCW DP < 0.68 ksc

• Purpose:
 Preventing damage to waterwall tubes due to insufficient cooling flow/circulation

 Preventing DNB (departure from nucleate boiling)

• Protection Delay:
 5 sec.
• Protection Check:
 Equalizing DP transmitters to simulate DP low.

April 21, 2020 PMI Revision 00 15

April 21, 2020 PMI Revision 00 16
 12. TOTAL AIR FLOW < 30%
• Arming:
 Always armed
• Logic:
 Total Air Flow (Primary Air + Secondary Air) < 30% of full load air flow (30% of 1800
Tph = 540 Tph)

• Purpose:
 Ensuring absolute minimum required quantity of air flow even during startup

 Preventing localized accumulation of unburnt oil during startup

• Protection Delay:
 0 sec - INSTANT.
• Protection Check:
 Actual.

April 21, 2020 PMI Revision 00 17

April 21, 2020 PMI Revision 00 18
 13. REHEATER PROTECTION
• Arming:
 HP bypass AND LP bypass charged for the first time > 2%
• Logic:
 Generator Circuit Breaker Open AND (HP bypass OR LP bypass Fail to Open)
OR
Reheater Inlet (HP) OR Outlet Path (IP/LP) Blocked

• Purpose:
 Ensuring absolute minimum required quantity of air flow even during startup

 Preventing localized accumulation of unburnt oil during startup

• Protection Delay:
 10 sec.
• Protection Check:
 Actual.

April 21, 2020 PMI Revision 00 19

April 21, 2020 PMI Revision 00 20
April 21, 2020 PMI Revision 00 21
 14. LOSS OF 24V DC
• Arming:
 Always armed
• Logic:
 If 24V supply to any 2 MFT panels is lost, it will initiate a hardwired MFT protection
through 220V contactor circuit.

• Purpose:
 If 24V fails, the processors cannot execute any logic, leading to unsafe condition

• Protection Delay:
 0 sec – INSTANT.

• Protection Check:
 By 24V breaker simulation in MFT panel.

April 21, 2020 PMI Revision 00 22

 15. LOSS OF 220V DC
• Arming:
 Always armed
• Logic:
 If 220V supply to any 2 MFT panels is lost, it will initiate a soft MFT protection through
processor logic.

• Purpose:
 If 220V fails, backup protection for 24V failure will be unavailable.

• Protection Delay:
 2 sec.

• Protection Check:
 By 220V breaker in MFT panel.

April 21, 2020 PMI Revision 00 23

 17. 2/3 PROCESSORS FAIL/FROZEN
• Arming:
 Always armed
• Logic:
 If any 2 MFT processors out of 3 go into failed state, or if any 2 MFT processors go into
frozen output state, it will initiate MFT protection.

• Purpose:
 This ensures that at least 2 processors are in healthy condition at any point of time
when boiler is in service.

 Failure of processors leads to unsafe condition

• Protection Delay:
 0 sec - INSTANT.
• Protection Check:
 By actually creating frozen output state in processors.

April 21, 2020 PMI Revision 00 24

 17. 2/3 PROCESSORS COMMN FAIL
•Arming:
 Always armed
• Logic:
 If any 2 MFT processors out of 3 stop communicating with the Ethernet network
(redundant net-A and net-B), they will initiate MFT protection

• Purpose:
 This ensures that at least 2 processors are communicating properly at any point of
time when boiler is in service.

 Failure of communication leads to malfunction of protection circuit

• Protection Delay:
 0 sec - INSTANT.
• Protection Check:
 By actually isolating network connections of the processors.

April 21, 2020 PMI Revision 00 25

 18. EMERGENCY TRIP
• Arming:
 Always armed
• Logic:
 If both Desk Emergency Push Buttons pressed together (OR)
If both Backup Panel Push Buttons pressed together (OR)
If MFT is confirmed through popup from any workstation PC

• Purpose:
 This facility allows the operation desk engineer to directly trip the boiler in case of any operational emergency eg.
Boiler Tube Leakage, Furnace excessive Clinkering, HFO oil leakage during startup, turbine related emergencies etc.

• Protection Delay:
 0 sec - INSTANT.
• Protection Check:
 By actually operating push buttons/through PC.
April 21, 2020 PMI Revision 00 26
 POST-TRIP PURGE FANS TRIP
• Arming:
 Boiler not firing fuel for 5 min (MFT may or may not be reset)
• Logic:
 If furnace pressure very high > 150 mmwc OR very low < -175 mmwc (AND)
Air Flow > 30% THEN
TRIP all ID Fans and FD Fans

• Purpose:
 This protection safeguards furnace against furnace pressure very high OR very low
when boiler is NOT firing.

• Protection Delay:
 0 sec – INSTANT (5 min delay in arming circuit)

• Protection Check:
By simulation at source.

April 21, 2020 PMI Revision 00 27

 RUNBACK – GRADED MILL TRIP
• Arming:
 More than 4 mills in service
• Logic:
 If any major auxiliary (eg. ID, FD, PA, BFP) trips and standby is not available, unit load
is automatically reduced according to the new capability

 Mills are tripped one by one starting from top running mill, at 2 sec delay, until 4
running mills from bottom remain.

• Purpose:
 This interlock achieves the fastest possible load reduction, and requires NO
intervention of desk engineer

• Protection Delay:
 Varies from 1 sec to 1 min according to type of auxiliary
• Protection Check:
 Simulated at initiating point.

April 21, 2020 PMI Revision 00 28

April 21, 2020 PMI Revision 00 29
 THANK YOU …
QUESTIONS ?

April 21, 2020 PMI Revision 00 30

 P&I OF BOILER AUXILLARIES
A. FD FAN
START PERMISSIVES
• Blade pitch position minimum.
• Discharge damper fully closed.
• Lube oil pressure adequate.
• Control oil pressure adequate.
• Oil tank level normal.
• Bearing temperature not high.
• One ID Fan running AND other FD fan not
running.
OR Both ID Fan running

April 21, 2020 PMI Revision 00 31

 TRIPS
• Fan bearing temperature very high
• Post purge furnace pressure very high/ very low
• Outlet damper fail to open in set time (3 min)
• No ID fan running or one ID fan and one FD fan
already in service.

April 21, 2020 PMI Revision 00 32

 PA FAN
START PERMISSIVES
• Blade pitch minimum
• Lube oil pressure adequate
• Control oil pressure adequate
• Bearing temp. not high
• Discharge damper closed.
• Lube oil tank level adequate
• No MFT & Cold air damper closed
• At least one FD fan is running and
• PAPH A/B in service & respective air inlet/ outlet
dampers are open
April 21, 2020 PMI Revision 00 33
 TRIPS
• Fan bearing temperature very high.
• Trip from FSSS (MFT).
• Discharge damper fails to open.

April 21, 2020 PMI Revision 00 34

 ID FAN
START PERMISSIVES
• Hyd. coupling Scoop position minimum.
• Inlet guide vane position minimum.
• Bearing temperature not high.
• Oil temp. and oil level in Hyd. coupling OK.
• Lube oil pressure adequate.
• Both inlet and outlet dampers closed.
• Other ID fan not running or Any FD fan running.

April 21, 2020 PMI Revision 00 35

 TRIP CONDITION
• Fan/Motor bearing temperature very high.
• Lube oil pressure very low.
• Post purge furnace pressure Hi/Low from FSSS.
• Discharge dampers/ suction damper fail to open
within specified time (3 min.)
• Hydraulic coupling bearing temp. very high
• Hydraulic coupling oil temp. very high.

April 21, 2020 PMI Revision 00 36

 SGWC PUMPS: (CC Pumps)

PERMISSIVES

• Discharge valve 1 open.

• Discharge valve 2 open.
• Motor cavity temp. not high.
• Pump cavity – suction manifold differential
temp. not high.
• Motor cooling water flow adequate.

April 21, 2020 PMI Revision 00 37

 TRIPS

• Any of the discharge valves not fully open.

• Motor cavity temp. high (60 deg. C) for more
than 5 Sec.
• Electrical protection trip/ EPB pressed.

April 21, 2020 PMI Revision 00 38

 Run back operation
• Tripping of PA Fan or FD Fan
• PA header pressure low/very low
• Sequential tripping of Mills/Feeders

April 21, 2020 PMI Revision 00 39

April 21, 2020 PMI Revision 00 40