1

I. Support / Guide Bearing Oil Circulation Unit with

100% Standby

4
5

Rotor Stoppage Alarm consists of a Magnetic Sensor (GO Switch) operated by Vanes
mounted on the Air Heater Trunnion. It the Vanes fail to pass under the Magnetic
Sensor connected to DDCMIS within the Set Time interval, the logic in DDCMIS
transfer the out put initate an Alarm in the DDCMIS panel and warn the operator
that the Rotor is slowing down/stopped.

Control Requirement
An Alarm initiated by the contacts provided in the BOP C&I DDCMIS is to alert the operator
about the Rotor slowing down/stopped condition.

Principle of Operation

IV. Fire Detection System (FDS)

Fire Detection System senses an undue Temperature Rise in the Air & Gas Flow
Streams of the Air Heater, and gives an early warning to DDCMIS at Remote about a
possible Fire situation.
Fire Detection System consists of a Set of Thermocouples located strategically in the
Air Heater Flow Streams, and is connected to DDCMIS at Remote, which measures at
Set Intervals the Temperature of each Thermocouple & compares it with its Set Point.
In the event of a measured Value being more than the Set Point for more than one
Rotor revolution time, an Alarm contact is closed in the DDCMIS Scan System. This
contact is used in the Plant Annunciation System, to alert the Operator of a possible
Fire Situation demanding immediate attention.

Scope of Supply for each System

2 sets per Air Heater(HE/CE), each set consisting of 6 Nos individual Thermocouple
Assembly for Primary APH & 2 sets per Air Heater(HE/CE), each set consisting of 9
Nos individual T/C assembly for Secondary. Each individual Thermocouple Assembly
is of Duplex (wire dia 1.0 mm) Chromel Alumel MI Ungrounded Thermocouples with
integral Terminal Box.

Design Features for APH Fire Sensing System in DDCMIS

(1) No. of Channels : 12 points for each Primary APH & 18 points for each
Secondary APH
(2) Temperature Range : 0 - 500C (Normal)
(3) Type of Input
: 'K' type Thermocouple,Duplex
(4) Scan Time setting : 3 Seconds (Recommended)
(5) No of Alarm Setting : One for High for each chanel or common for all chanels
(6) Alarm Relay operating condition & Set point : High alarm, 450 C

General
Simultaneous Scanning & Display shall be provided for all channels. If any one of the
channels is sensing abnormal condition, an Alarm shall be initiated after a delay of 1 minute.

V. Inspection Light Assembly (ILA)

To find the cleanliness of the Cold End of the Air Heater, a Glass Faced Observation Port & a
Vapour Proof Light is provided (to be located in the Air Inlet Duct). By switching on the Light,
one can clearly see the Cold End Elements through the Glass Observation Port.

Power Supply : 230 V 10%, 1Ph, 50 Hz 5%, AC, 500 W.

VI. Air Heater Deluge System

Air Heater Fires are very rare. In an unfortunate event of such a Fire, Deluge System is
provided to quench the same. This consists of Headers with special Nozzles strategically
located in the Air Heater in the Gas Inlet,Gas Outlet & Air outlet. Water Supply is provided to these
Headers through a set of Valves, Strainers, and Piping.
For each Header, two Isolating Valves are required. Also, a Drain Valve is to be introduced to
let-off any Water leaking past the Main Valve. This is recommended to avoid Water going into
the Air Heater and causing Plugging & Fouling problems during normal operation. Blow off
connection is provided in the Strainers and the Valve has to be installed in this line for
Drainage. Pressure Gauges are also provided to indicate the Water Pressure during Deluging.
In the event of an Alarm from Fire Sensing Device, the Operator has to go near the Air Heater
to check the possible Fire situation. If there is a Fire, then the Deluge System and the Water
Washing system Valves shall be opened manually.
Deluge System can also be used for Water Washing purposes. In case of Fire, both
Water Wash and Deluge System shall be used.

To be read along with :

Drg No : 2-00-114-22342 -- Scheme of APH with Instrumentation(Primary)
Drg No : 2-00-114-22344 -- M&C Schedule for scheme of APH with Instrumentation
Drg No : 2-00-114-22343-- Scheme of APH with Instrumentation(Secondary)

Drg No : 2-00-114-22345 -- M&C Schedule for scheme of APH with Instrumentation

Drg No : 1-52-220-02211 -- General arrangement of primary APH.
Drg No : 3-52-220-02054 --GAD Notes for air preheater

VII. Air Heater Water Washing

For off-load Washing of the Air Heaters, a set of Washing Manifolds with Nozzles are provided
in the Cold & Hot ends of the Air Heater. Water Supply is provided to these Headers through a
set of Valves, Strainers, and Piping.
The Water Supply Line has to be isolated by means of Stop Valves. A Drain Valve is also to be
added to let off any Water leaking past the Main Valve. This is recommended to avoid Water
going into the Air Heater and causing Plugging & Fouling problems during normal operation.
Blow off connection is provided in the Strainers and the Valve has to be installed in this line for
Drainage. Pressure Gauges are also provided to indicate the Water Pressure during Washing.

Note : In case of Fire, both Water Wash and Deluge System shall be used.

1. All the items marked within the Scope Mark in the Scheme of Air Preheater with
Instrumentation (Drawing No. 2-52-600-02759 & 02762), are supplied by BHEL, Ranipet.
2. All the Signals are taken to and processed through DDCMIS.
3. Local Junction Boxes for termination of wiring from field equipments, cables
from field equipment to local junction box are arranged by BHEL/TRY.
4. Incoming power supply cables for Motors, Motor starters, Instrumentation cables from
Local Junction Box to DDCMIS Panels, Remote indicators, Alarms, Interlocks are
arranged by NTPC.
5. a. Incoming power supply cable for ON/OFF switch Light assembly box are by NTPC
b. Cables between ON/OFF switch Light assembly box and Vapour proof light
are by BHEL/RANIPET.
6. Power and Control cables for APH soot blower are arranged by BHEL/TRY.
7. Air Motor solenoid valve operation is from DDCMIS by NTPC. The cabling
between DDCMIS Panel to Air Motor solenoid valve are by NTPC.
8. a. Fire sensing Compensating cables from T/C terminal box to Temperature
Transmitter are arranged by BHEL/TRY.
b. Compensating cables from Temperature Transmitter to DDCMIS Panel
are by NTPC.
c. Supply of Temperature Transmitter by NTPC.
9. a.Cables from RTD(TE) terminal box to Temperature Transmitter are arranged
by BHEL/TRY.
b. Cables from Temperature Transmitter to DDCMIS Panel are by NTPC.
c. Supply of Temperature Transmitter by NTPC.
10.Cooling Water, Water Wash, & Deluge Piping up to APH terminal point by
BHEL/Piping Centre.
11.Service Air Piping up to Air Receiver & also from Air Receiver to APH
terminal point by BHEL/Piping Centre.

IX. Scope of Supply

An Oil Carry-Over Detector is provided in the Gas Inlet Duct having Water Inlet & Outlet
connections through Flexible Hoses to circulate Cooling Water of 0.5 m3/Hr at a Pressure of 5
Kg/Cm2(g) maximum.
Oil Carry-Over Detector is a Water-Cooled Lance to be located in the Gas Inlet Duct just above
the Air Heater. Circulation of Cooling Water maintains the Lance Temperature at 90C or
below, which would cause any unburnt Oil Vapour in the Flue Gas Stream to condense. This
Lance should be withdrawn from the Duct by an Operator once in every 15 minutes during
Initial Firing of a Cold Furnace or Restarting after a Hot stand-by, such that Condensed Oil
could be observed and corrections in Burner Settings made.

VIII. Oil Carry-Over Detector

Sharma
Date: 2014.03.07
14:55:34 IST
Reason: CAT II
Location:
NTPCEOC

Each of the Support & Guide Bearing is provided with an Oil Circulation Unit having 100%
standby. Since the Bearing Housings are large in size, they are treated as Oil Sump. The Oil
Circulation Unit supplied by us is as shown in the Scheme.
The Oil Circulation Unit is not to be kept operating continuously. It is only required to
operate whenever the Bearing Oil Temperature exceeds a Set Point (40C for SB &
GB). For this purpose, 2 Nos Temperature Element Pt 100 RTD is provided in each
SB/GB which is connected to DDCMIS. It is to be noted that due to high viscosity of the
oil used in the oil circulation unit, the pump has to be started only after the oil reach the
pre determined temperature set in the DDCMIS.
A Platinum 100 RTD is provided in each Bearing Housing for connection to DDCMIS & to
generate Alarm whenever the Oil Temperature exceeds the permissible limit of 70C.

Control Requirements

(1)

(2)

(3)
(4)

III. Air Heater Rotor Stoppage Alarm (RSA)

that the Air Motor is running. Since Air Motor is an emergency drive, we recommend physical
verification of the running by an Operator.

Power Supply : 230 V 10%, 1Ph, 50 Hz 5%, AC, UPS, 50 W.

Caution : The fact that Air Pressure available at the Air Motor inlet is not a positive indication

Before the Air Heater is put into operation, Compressed Air Supply must be ensured. (For
this, NC contact of Pressure Transmitter HLD01 CP201, provided to initiate Air Pressure Low Alarm
located before the Solenoid Valve, can be used).
The Solenoid Valve is to be Interlocked with the Power Supply to the Main Motor so that
when the Power Supply to the Main Motor fails, the Valve will automatically open and admit
Compressed Air to the Air Motor for emergency operation. If the power supply to the
solenoid valve is taken from the UPS, then suitable interlock to de-energise the solenoid
valve in case of power failure to the electric motor is to be ensured. For this purpose, a
Solenoid Valve of de-energies to open type is provided in the Air Line to the Air Motor.
A Pressure Transmitter HLD 01 CP201 is provided upstream of the Solenoid Valve in the
Air Line to initiate Remote Alarm when the Air Pressure decreases below the Set Value.
A Pressure Transmitter HLD 01 CP202 is provided just before the Air Motor down stream of the
solenoid value to initiate an alarm in DDCMIS when the Air Pressure at the Air Motor inlet
decreases below a Set Value. This Pressure transmitter ensures Solenoid Valve open condition &
availability of Air Pressure at Air Motor inlet.

Control Requirements

Air Motor is provided in the Air Heater Drive for emergency operation in case of electric power
failure to Main Drive Motor when the Air Heater is operating at Full Load and also to rotate the
Rotor during Water Washing. It is to be positively ensured that clean, dry Compressed Air is to
be supplied to the Air Motor.

II. Air Motor HLD01 AE001 (Emergency Drive)

(1) When the Oil Temperature reaches in 1 outof 2 temperature elements Set Value (40C
for SB & GB) in the DDCMIS, the Main Pump must be started.
(2) If the Main Pump is inoperable, the Standby Pump must be started manually, and an
Operator shall physically verify the cause for the failure of the Main Pump Motor and initiate
corrective action. If customer is very particular about auto starting of the Standby Pump,
then the same can be done if the Temperature of the Lub Oil is more than 40C for SB &
GB. However, the cause for the failure of the Main Pump has to be physically verified by an
Operator and corrective action to be initiated.
(3) If the Flow Switch does not actuate within a period of 3 to 5 minutes after starting of the
Main Pump or the Standby Pump, an Alarm is to be initiated in the DDCMIS for 'NO flow'.
This alarm may be bypassed when the Temperature of the Oil is lower than the Set Value
and the Pumps are not running.

BHEL has not replied to our comment:

{This should be "automatically" instead
of "manually" inline with the Write up on
Boiler interlock submitted by BHEL and
inline with earlier NTPC projects.}

It is not advisable to allow the Air Heater Rotor to be stopped when high Temperature Gases
are flowing through it, since this may cause Unequal Expansion and pose problems for
restarting the Rotor. Rotor Stoppage Alarm HLD 01 CS201 is provided in the Air Heater to
annunciate the slowing down or stoppage of the Rotor at DDCMIS panel.

Digitally signed
Signature Not
Verified
by Rakesh

DRAWING NO.

A
ut
o

Size A2