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TRAINING PROGRAMME FOR POWER SECTOR EXECUTIVES ON CFBC BOILERS CONTROLS & INSTRUMENTATION
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SCOPE OF SUPPLY
ELECTRICALS, CONTROLS & INSTRUMENTATION
A. ELECTRICALS:
1.HT / LT Motors, Electrical actuators and Pneumatic actuators. 2.Local push button stations for soot blowers. 3.Boiler sootblower LTMCC.
SCOPE OF SUPPLY
B. INSTRUMENTATION & CONTROLS: 1. Local gauges for pressure and temperature measurements. 2. SH, RH and drum metal temperature measuring thermocouples. 3. Bearing temperature measurement of PA, ID, SA fans and their drives, vibration monitoring system for PA, SA & ID fan bearings (single axis), HT motor winding temperature measurement, SA & PA flow element pressure and differential pressure switches for startup burners & lances etc.
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SCOPE OF SUPPLY
4. Impulse lines along with fittings (same as that of parent material )for instruments in pressure parts and non pressure parts. 5. Instrument air supply lines 6. Lignite feeder control panel ( VFD based). 7. Instrument cables (Screened ) upto local junction box (for process switches). 8. Local junction boxes (for terminating SH/RH & drum Metal Temperature Measurement thermocouples).
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SCOPE OF SUPPLY
9. Cable trays (perforated) for Instrument cables upto JB. 10.One no. Electronic water level indicator (single vessel) - BHELVISION 20. 11. Local Controller for SH & RH ERVs 12.BMS Panel (Supply by BHEL EDN Bangalore). 13. Soot blower Panel for auto sequential operation of soot blowers (Supply by BHEL EDN Bangalore).
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SCOPE OF SUPPLY
14. Soot blower Panel for auto sequential operation of soot blowers (Supply by BHEL EDN Bangalore). 15. Fuel oil flow meter (Positive displacement type). 16. Spray flow measurement (orifice) for SH & RH.
EXCLUSIONS
1. Lighting at site and boiler area. 2. Complete electrical power distribution system like transformers, HT switchboards, boiler HTMCC, boiler LTMCC ,Boiler emergency LTMCC etc. 3. Earthmat, earth risers, earth pits, below ground and above ground earthing. 4. All HT, LT power and control cables including those interconnecting soot blower control panel to SB MCC & SB MCC to local push button station /Soot blowers. This also includes cable trays and accessories. 7
EXCLUSIONS
5. Lightning arrestor and Aviation lamps for chimney. 6. All remote instruments. 7. Distributed control system (DCS). 8. Power distribution boards. 9. Electrical power supplies (both AC and DC). 10.Uninterrupted / Emergency power supply units (Both 3 Ph, 415 V, AC and 1Ph, 230 V, AC supply). 11. Emergency instrument air supply system.
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EXCLUSIONS
12. Air compressor and its accessories.
13. Intercommunication and telephone systems. 14. Instrumentation cables and cable trays between Field Junction Box and DCS marshalling rack. 15. Complete online flue gas emission monitoring system including Oxygen, SO2, NOX, SPM, CO analyzer etc. 16. Complete online steam and water analysis system including pH, conductivity, silica analysers etc. 17. Feed water and Main steam flow elements (PEM Supply). 9
EXCLUSIONS
18. Thermocouples along with thermowell for remote monitoring and controls 19. Process transmitters (Smart type) including hand held configurator. 20. Fire detection and alarm system 21. Ventilation and AC equipment. 22. All other equipments other than those specifically included under scope of supply.
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LIGNITE BUNKER 1
LIGNITE BUNKER 2
LIMESTONE SILO 1
PLANT AIR LIMESTONE 1 FLUID AIR LINE 1
LIMESTONE SILO 2
PLANT AIR
LIGNITE CONVEYOR 1
LIGNITE FEED CONTROL
LIGNITE CONVEYOR 2
LIGNITE FEED CONTROL
PURGE & SEAL AIR LIMESTONE 1 FLUID AIR LINE 2 SV LIGNITE AL FDR1 PURGE VLV LIMESTONE 1 AL FDR 1 LIMESTONE SPEED CONTROL LIMESTONE 1 AL FDR 2 LIGNITE AL FDR1 PURGE & SEAL AIR
CYCLONE 1
CYCLONE 2
LIGNITE AL FDR2
SV LIGNITE AL FDR1 PURGE VLV LIMESTONE 2 AL FDR 1 LIMESTONE SPEED CONTROL LIMESTONE 2 AL FDR 2
PLANT AIR
COMBUSTOR
LIGNITE GATE VLV 1 LIGNITE GATE VLV 2
PLANT AIR
SEAL POT 1
SEAL POT 2
BED ASH SYSTEM BED ASH TO COMBUSTOR BOTTOM ASH TRANSPORT (REF DRG.NO:0-97-400-80016) FILTER CLEANING SYSTEM BED MTL FLTR AIR FAN
SH2A
RH1
SH2B
EVAP
SV BED MTL FLUID AIR VLV BED MATL AL FEEDER SV BED MATL FEED GV
COOLING WATER
COOLING WATER
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START UP SEQUENCE
MANUAL START OF ID FAN FUNCTION GROUP 1 OR 2 MANUAL START OF FN. GROUP FOR OTHER ID FAN FN GROUP ID FAN IN OPERN. YES PUT ALL FN GROUP TO AUTO MODE -FG FANS & BLOWERS -FG BOILER PURGE -FG FANS -FG PA FAN 1 -FG PA FAN 2 -FG SA FAN 1 -FG SA FAN 2 -FG FBHE BLOWERS -FG ID FAN 1 -FG ID FAN 2 NO
MANUAL START OF FN GROUP FANS & BLOWERS -SEAL POT BLOWERS ON -ASH COOLER BLOWERS ON -FN GROUP OF SELECTED SA FAN AUTO ON -FBHE EMPTY CHAMBER BLOWER ON -FG OF SELECTED PA FAN AUTO ON -ALL AIR CONTROLLERS AUTO
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LOAD >50% REDUCE LOAD OF SUB MANUAL START OF FG FANS -START OF 2ND FG SA FAN -START OF 2ND FG PA FAN -START OF 2ND FG ID FAN
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U N IT P U R G E T R IP
Y
S /U B U R N E R S
T< 600
T> 600
Y
T< 750
Y Y
T< 550
W A R M R E S TA R T
T R IP
Y
B E D L A N C E S
T< 750
T> 750
T< 750
T> 750
Y Y
T< 700
T R IP
S O L ID F U E L
B E D L A N C E S C O F IR IN G O P T IO N A L
Y Y
T~ 850
Y
T> 600
T< 725
S H U T D O W N
Y
N O R M A L O P E R A T IO N
H O T R E S TA R T
T< 960
N
B P # 1 T R IP
T> 960
N B L R # 3 T R IP B L R # 1 T R IP B L R # 2 T R IP
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BOILER PROTECTION 1
AT THIS TOP MOST LEVEL OF TRIP CONDITION, ALL DRIVES, FANS, BLOWERS, START UP BURNERS, LANCES AND LIGNITE FEEDER ETC., EXCEPT ID FANS WILL TRIP. OVER PRESSURE PROTECTION BOILER IS PROTECTED FROM DAMAGE DUE TO OVER PRESSURE WHEN CONVECTIVE PASS INLET PRESSURE IS >40 mBAR. THE SELF REGULATED OVER PRESSURE RELIEF DAMPER LOCATED AT THE ESP INLET WILL OPEN AUTOMATICALLY. PRIOR TO THIS WHEN PRESSURE IS >30 mBAR, ALL THE FANS AND BLOWERS (EXCEPT ID FAN) AND FIRING SYSTEM WILL TRIP. ID FAN CONTROL WILL FULL OPEN THE IGV.
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BOILER PROTECTION 1
BOILER TRIP CONDITION BOILER PROTECTION-1 WILL ACTUATE AT ANY ONE OF THE FOLLOWING CONDITIONS OCCUR. 1.EMERGENCY PUSH BUTTON PRESS 2.FEEDWATER TANK LEVEL VERY LOW 3.DRUM LEVEL VERY LOW (-305MM) 4.BOTH ID FANS (I&II) SPEED VERY LOW(<) 5.BOTH ID FANS (I&II) OUTLET DAMPERS CLOSE 6.INSTRUMENT AIR PRESSURE VERY LOW <4.5 KG/CM2 7.MAIN STEAM PRESSURE STOP VALVE NOT OPEN WHEN MS PRESSURE >20 BAR 8.PRESSURE INLET CONVECTIVE PASS >30MBAR
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BOILER PROTECTION 1
9. PRESSURE INLET TO ID FAN I&II <-40 MBAR 10. HPBYPASS NOT OPEN WITHIN 2 SECONDS WHEN TURBINE TRIP. 11. COMBUSTOR MIDDDLE TEMPERATURE >9500C 12. COMBUSTOR LOWER TEMPERATURE >9500C 13. TEMPERATURE OUTLET CYCLONE 1 >9500C 14. TEMPERATURE OUTLET CYCLONE 2 >9500C 15. TOTAL COOLING WATER FLOW VERY LOW 16. MAIN STEAM TEMPERATURE VERY HIGH >5600C 17. RH STEAM TEMPERATURE VERY HIGH >5600C
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BOILER PROTECTION 2
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BOILER PROTECTION 2
THIS PROTECTION WILL ACT WHEN COMBUSTOR MIDDLE OR LOWER TEMPERATURE IS <5500 C OR PRIMARY AIR FLOW <16 KG/CM2 OR EMERGENCY STOP FOR LANCES WHEN THIS CONDITION OCCURS, ALL THE BED LANCES WILL BE PUT OFF.
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BOILER PROTECTION 3
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BOILER PROTECTION 3
THIS WILL ACT WHEN COMBUSTOR MIDDLE OR LOWER TEMPERATURE IS <6500 C. WHEN THIS TRIP CONDITION OCCURS ALL THE DRIVES RELATED TO LIGNITE FEEDER AND LIMESTONE FEEDING SYSTEM WILL TRIP. IE CONVEYOR , AIR LOCK FEEDER & GATE VALVES.
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THIS IS TO PROTECT THE RH BUNDLES IN FBHE 1. WHEN RH OUTLET STEAM TEMPERATURE IS VERY HIGH (>5600C) IT WILL ACTUATE THE RH PROTECTION WHICH WILLTRIP THE FBHE 1 BUNDLE CHAMBER BLOWER AND CLOSES THE RESPECTIVE SPIESS VALVE IN SEAL POT 1. THIS WILL REDUCE THE PICK UP IN RH1.
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ASH DISCHARGE VALVES ARE LOCATED AT 7 PLACES TO FACILITATE THE DISCHARGE OF ASH INVENTORY. THE DISCHARGE WILL BE USEFUL FOR CONTROLLING THE COMBUSTOR TEMPERATURE, RH1 STEAM TEMPERATURE, COMBUSTOR DP & LOAD CONTROLS.
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AH TOP BLOCK 17 18 19 20
} }
} }
S.A 1
SH II 2 RH II 4
P.A
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24 SH II 6 ASH RH II 8
FBHE
400
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AH MIDDLE BLOCK
} } } }
LEGEND: ECO 10 ECO 12 1. LONG RETRACTABLE SOOT BLOWER AT LEFT SIDE 2. LONG RETRACTABLE SOOT BLOWER AT RIGHT SIDE 3. HALF RETRACTABLE SOOT BLOWER AT LEFT SIDE 4. HALF RETRACTABLE SOOT BLOWER AT RIGHT SIDE
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P.A
AH BOTTOM BLOCK
ECO 14 ECO 16 NOTES: 1.LAMP NO GLOW - BLOWER NOT IN OPERATION / BYPASSED 2. RED FLASHING - FORWARDING 3.RED SLOW FLASHING - RETRACTING 4. RED STEADY GLOW - BLOWING COMPLETED
TO ESP
ASH
ASH
600
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SOOT BLOWERS ARE SUITABLY LOCATED TO CLEAN THE HEATING SURFACES OF SIPERHEATERS, REHEATERS AND ECONOMISERS IN THE CONVECTIVE PASS & AIR HEATER SURFACES IN THE AH PASS. CLEANING OF THE HEATING SURFACES WILL ENABLE BETTER HEAT TRANSFER & ALSO REDUCE THE PRESSURE LOSS IN THE SUPERHEATERS, REHEATERS, ECONOMISERS & AIR HEATERS.
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DRUM EM ERGENCY DRAIN TO IBD (BW055) M S LINE SUV REG VALVE (M S104) DRUM CBD LINE M AIN ISO (BW059) HOT REHEAT LINESTART UP VENT ISO (M S085)
DC REQUIREMENT
EMG.BOILER FEED PUMP - DISCHARGE ISO VLV EMG. FW ISO VLV - SPRAY TO HP BYPASS DURING STATION BLACK OUT EMG. FW ISO VLV - SPRAY FOR MSL STEAM TO DEAERATOR DURING BLACK OUT LIGNITE GATE VALVE 1 LIGNITE GATE VALVE 2
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