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Boiler Controls &

Instrumentation

K Karthikeyan
Manager
Controls & Instrumentation
BHEL, Tiruchirappalli
Email : karthi@bheltry.co.in

Boiler C&I

INTRODUCTION
PART I - BOILER
PART 2 - INSTRUMENTATION
PART 3 - CONTROLS

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler
Controls &
Instrumentation

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler C&I -Functions

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Broad engineering activities


Control systems
engineering
Instrumentation
engineering
Electrical systems
engineering
New product development
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Functions
Proposal Engineering
Contract Engineering
Product Engineering
Quality Assurance &
Control
Field Engineering
Research & Development
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Proposal Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler Controls &


Instrumentation

Boiler C&I

Proposal Engineering

Scope of Work
Project Estimate
Offer submission
Offer evaluation
by customer

Award of
contract
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler Controls &


Instrumentation

Boiler C&I

Proposal Engineering
In summary, the purpose is to draw-up
- Scope of Work
- Project Estimate
of the project.

Deliverables :
-

Estimable quantity(BOM)- main and spares


Datasheets
Descriptive offers of packages &
Preliminary design sketches(P&IDs, GA).
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Scope of Work

Arrived based on a broad specification

prepared by the customer/consultant.


Individual system scope identified gets
recompiled into a project scope of work .
Project scope document includes scope of
work , terminal points & exclusions

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Scope of Work

The typical scope covered in Boiler C&I


discipline include

Furnace safeguard Supervisory system

Secondary Air Damper control system

Soot blower control system

Boiler area field instruments

Associated cable & accessories.


Electricals(MCC, elevator etc.)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Offer evaluation
The offers get evaluated at the customer
end.
Customer awards the contract on a
technically qualified bid with the lowest
price.
The award of contract is indicated by a
Letter of Intent received from the customer.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Award of
contract

The offers get evaluated at the customer


end.
Customer awards the contract on a
technically qualified bid with the lowest
price.
The award of contract is indicated by a
Letter of Intent received from the customer.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Contract Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Contract Engineering
Packages
SG integral C&I(Trichy)
Station C&I(PEM or customer)- in
case of BTG or Turnkey
SG integral electricals(Trichy)
Station Electricals(PEM or customer)in case of BTG or Turnkey
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Contract Engineering
The role involves system level contract
coordination for the boiler C&I area.
Applicable PGMA List
Sub Delivery check list.
Boiler Contract Regular activity(BCR)
schedule
00 PG list(erection documents).
Applicable O&M documents.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Contract Engineering
System Engg. Documents involved :
Piping&Instrumentation
Diagrams(P&IDs)
Measurement & control
recommendations
Automatic control schemes
Interlock & protection schemes

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

P & I Diagram- Air & flue gas (portion)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Instrument schedule steam & water (sample)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Product Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Product Engineering
Detailed design of Boiler C&I
products & systems
Digital controls
Analog controls
Electrical systems &
cables
Field instruments
Special instruments
Actuators
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Product Engineering
Digital Controls

Burner management system.


Soot Blower control system
Analog Controls

Secondary air damper control system.


Auxiliary PRDS control system.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Product Engineering
Electrical systems

Control supply panels


LT Motor control centres
Power distribution panels
Field instruments

Switches & gauges for Pressure,Level &


temperature
Thermocouples
Flow elements
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Product Engineering

Special instruments

Flame scanner system


Acoustic steam leak detection system.
Electronic water level indicator.
Closed circuit television system.
Vibration monitoring system.
Flue gas analysers.
Steam and water analysers.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Product Engineering
Electrical and C & I engineering design
Release of indents for C & I sub-delivery items.
Evaluation of technical offers for bought-out
items
Technical Delivery Conditions (TDC)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Quality Control &


Assurance

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Quality Control &


Assurance
The role involves preparation/review of
following activity w.r.t C&I products &
systems

Prepare Standard Quality Plans (SQP)


Prepare Contract Quality Plans (CQP)
Review/Approve Vendor Quality Plans (VQP)
Issue Reference Quality Plans (RQP)
Prepare Inspection Check Lists (ICL)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Quality Control &


Assurance
Performing inspection at vendor works for
CI products & systems - bought-out items
Review & dispose Site Action Requests on
CI products & systems

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Field Engineering

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Field Engineering
The role involves
Providing technical support / trouble shooting of
C&I products / system during
- Erection & commissioning stage of project

- Operation after handing over to customer

Review & dispose Commissioning action requests


Review & dispose Contract closing pending
issues
Visiting sites to ensure smooth progress of C&I
site activity

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls &


Instrumentation

Research & Development

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Research & Development

n-house developed C&I systems & produ


Microprocessor based Gravimetric
coal feeder controls - BHELFEED
Microcontroller based Flame
moniotirng system - BHELSCAN
Acoustic steam leak detection
system BHELSONIC
Electronic water level Indicator
system- BHELVISION
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Basics

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
BOILER CLASSIFICATION

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

BHEL BOILERS
Power Boilers
Up to 600 MW rating(Coal, oil and gas fired - Subcritical)
Up to 800 MW - Supercritical
Nuclear steam generators
Up to 235 MW rating
Industrial boilers
Up to 450 Tonnes/hour rating
Fertilisers, Petrochemical, Steel & Paper industries
Wide range of fuels- Oil, Gas, BFG, Bagasse, Black liquor.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Bharat Heavy Electricals Limited - Tiruchirappalli

Schematic of a boiler

Boiler C&I
UTILITY BOILERS - ESSENTIAL COMPONENTS

Furnace & Circulation system


Superheaters
Reheaters
Economiser
Airheaters
Fans
Pulverisers
Raw coal feeders
Fuel firing system
Sootblowers

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
CIRCULATION SYSTEMS

Natural circulation
Controlled circulation
Once through

Circulation ratio :
Mass rate of water fed to the steam generating tubes to the
mass rate of steam generated.
Natural circulation
Controlled circ
Once through

6
4
1

Bharat Heavy Electricals Limited - Tiruchirappalli

BOILER CIRCULATION SYSTEMS

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
Fans

1.

Axial
Impulse type - IGV Control.
Reaction type - Blade pitch Control.

2. Radial
Inlet damper control, Variable speed control;
Variable speed control by two speed motor,
Hydraulic coupling or Variable frequency drive.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Radial
Fan- Tiruchirappalli
Bharat Heavy Electricals Limited

Boiler C&I

Axial Reaction
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
RADIAL FANS - SPEED CONTROL

- Flow proportional to Speed


- Flow proportional to (Impeller Dia)

- Head proportional to (Speed) 2


- Head proportional to (Impeller Dia) 2

Hence Variation in speed alters the performance

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

FANS IN BOILER - SCOPE

Primary air fans - Dries & transports Pulverised coal

Forced draft fans - Supplies Combustion air

Induced draft fans - Sucks Flue gas out of furnace

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

MILL - GRINDS COAL


Slow speed mills (Tube mills - 15 to 25 RPM)
Medium speed mills (Bowl mill, Ball and race mill
etc.- 50 to 100 RPM)
High speed mills (hammer mills directly coupled to
motor - 750 to 1000 RPM)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

RAW COAL FEEDERS


Scope :

CONVEY RAW COAL TO MILL

Volumetric - Rotary and drag link,


Types :

Gravimetric Endless belt type

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

AIRHEATER

Heat recovery equipment


Extract heat from Flue gas to heat primary & secy. Air
Types :

Regenerative type

Tubular type

( Rotating drive )

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
SOOTBLOWERS
Remove ash & slag from pressure part tubes

Types
Long retractable sootblowers - traverse & rotary motors
Half retractable sootblowers- traverse & rotary motors
Rotary blowers - rotary motor
Wall blowers - traverse & rotary motors
Furnace temperature probe - Used during boiler start up

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

FUELS & COMBUSTION


Fuels :

Coal

Oil Gas

H/C ratio
Natural gas 0.3

Fuel oil 0.1

Coal

Calorific value (kcal/kg )


Gas
10000 Oil 8000
Bituminous coal 3000-3500 Lignite
Coal burning methods
"On grate" In suspension"

0.07

2500

Fluidised bed

Three 'T's of combustion


Time
Temperature and
Turbulence.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FUELS & COMBUSTION

Rapid combustion

Short period of time

High temperature

Very turbulent flame .

&

Less turbulence and longer burning produces


fewer nitrous oxide.
In some cases combustion is delayed or staged
intentionally to obtain fewer nitrous oxide or to
obtain desired flame characteristics.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Instruments

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Instrumentation
representation- ISA

First letter

P-Pressure
T-temperature
F- Flow
A- Analytical

Succeeding letters

A- Alarm
I- Indicate
R- Record
Q- Integrate
C- Control
S- Switch
T- tansmitter
E- Element
P- Pocket
W- Well

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Boiler Controls

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
BOILER CONTROLS

Continuous control :
Objective

Enabling Automatic Operation.


Optimising operating performance.
On-Off control :
Objective

Supervise process operation for safety


Prevent process from entering unsafe condition.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
BOILER CONTROLS

Auto control system


Boiler Auxiliaries interlocks & protection system
Furnace safeguard supervisory system (FSSS)

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
Auto control system.

Master demand
Combustion and draft control
Feed-water control
Steam-temperature control

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Master demand

'Master demand' controls the boiler operation.


Set from unit load demand or main steam header pressure control
Master demand sets burners firing at a rate required for steam
production and corresponding air flow demand

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Combustion control

Fuel flow control


Air Flow Control
Coal mill control

Objective :
Fuel is consumed at a rate that exactly matches the Steam demand.
Fuel is consumed safely, so that the energy is released without risk to plant,
personnel or environment

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
Combustion control
Fuel FLOW

Air Fuel/Cross Limiting


STEAM
HEADER PRESSURE

FT

AIR FLOW

PT

FT

f(x)
P
A

I
T

SP
P
A

I
T

LO SELECT
Fuel CONTROL

Fuel Feed

SP
HI SELECT

P
A

I
T

AIR CONTROL

f(x)

Air Feed

AIR
DAMPER
Bharat Heavy Electricals Limited - Tiruchirappalli

67

Boiler C&I

Mill air flow and temperature control


Mill uses primary air For transporting coal from mill to furnace.
To "dry" coal.
Air flow to mill and mill outlet temperature are regulated using Hot
air damper and cold air damper respectively

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Feedwater control

Objective :
To supply enough water to the boiler to match the evaporation rate.
Water level in the drum indicates amount of water in boiler
Actual Steam Flow - Used to determine required feedwater during
transient conditions when level may not be accurate.
Difference between Actual steam flow and Actual Feedwater Flow is
added to the level error to form the Feedwater demand.
Feedwater demand drives the feed control station to adjust feedwater
sa as to maintain the drum level to normal value.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Feedwater control

DRUM

STEAM
PRESSURE
PT

FLOW
FT

f(x)

FEEDWATER

TEMPERATURE LEVEL PRESSURE


TE

LT

f(x)
X

FLOW TEMPERATURE

PT

FT

TE

f(x)
X

PRESSURE AND
TEMPERATURE
COMPENSATION

PRESSURE
COMPENSATION

f(x)

TEMPERATURE
CONDENSATION

SET POINT

A
M/A CONTROL
STATION

Typical single-drive control system. For simplicity, redundant


transmitters have not been shown on this typical control drawing.
See Figure 4A for ANSI/ISA-S5.1-1984 format.

f(x)

FINAL
CONTROL
DEVICE

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Steam temperature control


Objective:
To maintain a constant steam temperature at turbine inlet despite large load
swings .
Basic methods :
DESUPERHEATING (ATTEMPERATION)
Fine spray of comparatively cool water droplets into the vapour to reduce
steam temperature.

BURNER TILT POSITIONING

Raise/Lower the Fireball in the furnace by tilting burners upwards or


downwards.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Steam temperature control

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Secondary Air Damper Control

Two types of dampers Fuel air dampers & Auxiliary air dampers
Maintains proper windbox air flow distribution
0 to 30 % unit load, all auxiliary dampers modulated to
maintain windbox to furnace differential pressure
Above 30% unit load, BMS closes elevations of
auxiliary dampers that are not required for elevations of
fuel currently in service
Fuel air dampers are positioned on an elevation basis as a
function of the
corresponding coal feeder speed
High windbox to furnace differential pressure opens all
the secondary air dampers
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Steam temperature control


Cascade control used for Spray de-superheating loop
MS temperature error establishes the set point for SH DESH
outlet temp.
SH DESH outlet temp. error positions the spray control valve such
as to regulate the MS temperature within allowable limits.
Burner tilt responds to the lower of SH or RH outlet temp.
Spray control responds to the higher of SH or RH outlet temp.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

BOILER AUXILIARIES INTERLOCKS AND PROTECTION SYSTEM

Scope :
Sequence control of starting and protection &
interlocking of boiler auxiliaries
FD fans
ID fans
PA fans
Airheaters
Dampers
Valves

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

FURNACE SAFEGUARD SUPERVISORY SYSTEM

( FSSS )

This system takes care of interlocks required for


starting, supervising the operating and safe shut
down of the equipments connected with fuel firing
system.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Tangential Windbox

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

SECONDARY AIR

SECONDARY AIR

FURNACE PLAN CORNER DESIGNATION

FRONT WATER WALL

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
Fireball Tangential Firing

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
CAUSES OF FURNACE EXPLOSIONS
An interruption of
Fuel
or
Air supply or
Ignition energy

to the burners, sufficient to result in momentary loss of flames, followed by


restoration and delayed re-ignition of an accumulation.
Fuel leakage into an idle furnace and the ignition of the accumulation by a
spark or other source of ignition.
Repeated unsuccessful attempts to light-off without appropriate purging,
resulting in the accumulation of an explosive mixture.
The accumulation of an explosive mixture of fuel and air as a result of loss
of flame or incomplete combustion at one or more burners in the presence
of other burners operating normally or during lighting of additional burners.
The accumulation of an explosive mixture of fuel and air as a result of a
complete furnace flameout and the ignition of the accumulation by a spark
or other ignition source, such as could occur where attempting to light a
burner(s).
Purging with an airflow that is too high, which stirs up combustibles
smoldering in hoppers.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
CAUSES OF FURNACE IMPLOSIONS

A mal-operation of the equipment regulating the boiler gas flow,


including air supply and flue gas removal, resulting in furnace
exposure to excessive induced draft fan head assembly.
The rapid decay of furnace gas temperatures and pressure resulting
from either a rapid reduction in fuel input or a master fuel trip.
A combination of the two conditions indicated in a, b above has
resulted in the most severe furnace implosion incidents.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

FUNCTIONS OF FSSS
1. FURNACE PURGE SUPERVISION
2. SECONDARY AIR DAMPER MODULATION AND ON-OFF
CONTROL AND SUPERVISION
3. IGNITOR ON-OFF CONTROL AND SUPERVISION
4. LIGHT OIL ON-OFF CONTROL AND SUPERVISION
5. HEAVY OIL ON-OFF CONTROL AND SUPERVISION
6. PULVERIZER AND FEEDER ON-OFF CONTROL AND
SUPERVISION
7. FLAME SCANNER INTELLIGENCE AND CHECKING
8. BOILER TRIP PROTECTION.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

FSSS

F - FURNACE
S - SAFEGUARD
S - SUPERVISORY
S - -SYSTEM
FSSS ENSURES SAFE FURNACE OPERATING CONDITIONS DURING

START UP
LOW LOAD OPERATION
SHUT DOWN.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

SOME OF THE PRECAUTIONARY MEASURES TO ACHIEVE SAFE


AND RELIABLE OPERATION
FURNACE SHOULD BE PURGED BEFORE LIGHT UP
ADEQUATE IGNITION ENERGY TO EACH BURNER
ADEQUATE AIR SUPPLY TO EACH BURNER TO AVOID
FLAME OUT

OPTIMUM FURNACE PRESSURE

CORRECT AIR TO FUEL RATIO

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

FUNCTIONAL DIVISION OF LOGICS

UNIT LOGIC

ELEVATION LOGIC

CORNER LOGIC

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

TYPICAL CONDITIONS FOR FURNACE PURGE:


Heavy fuel oil trip valve
closed.
Heavy fuel oil nozzle valves
closed.
Light fuel oil trip valve
closed.
Light fuel oil nozzle valves
closed.
Flame scanners on each
elevation indicate no flame.
Air flow greater than 30%
and less than 40%

All pulverisers off.


All feeders off.
Pulveriser outlet gates
closed.
All hot air gates closed.
All cold air dampers not
greater than 5 open.
Both PA fans off.
No boiler trip existing.
All auxiliary air dampers
modulating.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

BOILER TRIP COMMAND IS INITIATED BY


LOW OR HIGH DRUM WATER LEVEL
BOTH I.D OR F.D ARE OFF
LOW OR HIGH FURNACE PRESSURE
REHEATER PROTECTION TRIP
TURBINE
LOSS OF ALL FUEL TRIP
LOSS OF UNIT D.C POWER
LESS THAN FIRE BALL AND LOSS OF AC AT
ELEVATION

MANUAL TRIP

UNIT FLAME FAILURE TRIP

INSUFFICIENT PRIMARY AIR

ANY

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

BOILER TRIP COMMAND RESULTS IN


STOPPAGE OF ALL FUEL INPUTS BY TRIPPING
1.
2.
3.
4.

ALL PULVERIZERS
ALL FEEDERS
ALL OIL GUNS
ALL IGNITORS

IT CLOSES
1. IGNITOR
2. LIGHT OIL TRIP VALVES
3. HEAVY OIL TRIP VALVES

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
Scanner Fan logic

Scanner duct to furnace DP when


low initiates a Scanner air fan -A
run command
If DP value remains low for more
than five seconds, scanner air fan -B
run command is issued.
If DP condition is low even after 10
seconds Loss Of Scanner Cooling
Air alarm is generated
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
Seal Air Fan Control

When either Primary Air Fan is on,


seal air fan A is automatically
placed in service.
If either Primary Air Fan is on & Seal
Air Header/Cold Air Duct DP is low,
the seal air fan is auto started.
When both seal air fans are on and
the Seal Air Header/Cold Air Duct DP
is not low,either seal air fan can be
stopped
manually.
Bharat Heavy
Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

PULVERIZER STARTING PROCEDURE

<

<

<
<

START
PULVERIZER ON FEEDBACK
OPEN HOT AIR GATE
WAIT TILL PULVERIZER COMES TO TEMPERATURE
( 140F )
START FEEDER ( AT MINIMUM FEEDER SPEED )
COAL FLOW INDICATOR OR PULVERIZER AMPERE (
( WITH IN 5 SECONDS )
FIFTY SECONDS
FEEDER SPEED RELEASED TO AUTOMATIC CONTROL
FUEL AIR DAMPER OPENED
FUEL AIR DAMPER MODULATED TO AUTOMATIC
CONTROL.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
PULVERIZER START REQUIREMENTS

FSSS

IGNITION ENERGY AVAILABLE

B.

ADEQUATE PRIMARY AIR

C.

D.C POWER AVAILABLE

D.

LOCAL PULVERIZER CONDITION SATISFACTORY

E.

IF NO OTHER FEEDER IS WORKING FUEL AND AIR


NOZZLE TILTS PLACED IN HORIZONDAL
CONDITION.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

CONDITIONS ( LOCAL ) TO BE SATISFIED TO START


RESPECTIVE PULVERIZER
A.

DISCHARGE VALVE OPEN

B.

SEAL AIR VALVE OPEN

C.

COLD AIR DAMPER OPEN

D.

PULVERIZER DAMPER OUTLET LESS THAN 200F

E.

FEEDER INLET GATE OPEN

F.

TRAMP IRON HOPPER VALVE OPEN.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

PULVERIZER IGNITION ENERGY AVAILABLE


A MINIMUM OF 3 OF THE 4 LIGHT OIL OR HEAVY OIL
NOZZLE VALVE OF THE ELEVATION JUST ABOVE OR
BELOW, ARE OPEN
OR
BOILER LOADING IS GREATER THAN 30% AND
PULVERIZER JUST ABOVE OR BELOW IS IN SERVICE AT
GREATER THAN 50% LOADING.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

MILL OUTLET TEMPERATURE CONTROL

HIGH PULVERIZER OUTLET TEMPERATURE (ABOVE 200F )


WILL
OPEN COLD AIR DAMPER
AND
CLOSE HOT AIR GATE.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

FEEDER CONTROL
A.

FEEDER RUNS AT MINIMUM SPEED UNTIL


INITIATING CONDITION IS CORRECTED, AT
WHICH TIME THE FEEDER WILL BE RETURNED
TO CONTROL.
A. PULVERIZER BOWL DIFFERENTIAL HIGH.
B. PULVERIZER AMPS. ABOVE MAXIMUM SET POINT.

B.

LOSS OF COAL FLOW AND LOW PULVERIZER


CURRENT
WILL TRIP THE FEEDER, OPEN COLD AIR
DAMPER AND CLOSE
HOT AIR GATE.
AFTER CORRECTIVE ACTION THE HOT AIR GATE IS
OPENED AND FEEDER IS RESTARTED.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

CONDITIONS FOR A PULVERIZER TRIP

PULVERIZER DISCHARGE VALVE NOT OPEN

LOSS OF UNIT DC POWER (FOR MORE THAN 2 SECONDS)

PULVERIZER IGNITION PERMIT NOT SATISFIED AND SUPPORT


IGNITION IS REQUIRED.

BOILER TRIP

PRIMARY AIR FAN TRIP

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

PULVERIZER SHUT DOWN SEQUENCE

<

<

<

START ASSOCIATED OIL ELEVATION


REDUCE FEEDER SPEED TO MINIMUM
CLOSE HOT AIR GATE
PULVERIZER OUTLET TEMPERATURE IS 120F
STOP FEEDER
WAIT FOR 2 MINUTES
STOP PULVERIZER
FURNACE STABILIZES
ASSOCIATED OIL LEVEL SHUT DOWN.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

PULVERIZER SHUT DOWN

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START ASSOCIATED OIL ELEVATION


REDUCE FEEDER SPEED TO MINIMUM
CLOSE HOT AIR GATE
PULVERIZER TEMPERATURE IS 120F
STOP FEEDER
TWO MINUTES
STOP PULVERIZER
FURNACE STABILIZES
SHUT OFF ASSOCIATED OIL ELEVATION.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS

ARRANGEMENT OF SYSTEM
FSSS - MAJOR PARTS

LOGIC CABINET
CONSOLE INSERT
SECONDARY AIR DAMPER PANEL
MILL PANEL
FIELD EQUIPMENTS
CUSTOMER SUPPLIED INTERFACE
EQUIPMENT.

Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I

Oil gun start sequence

HEA Advances
Atomising valve opens
Corner oil valve opens
HEA sparks
Flame scanner picks up flame
HEA retracts
Corner valve closes if flame is not
sensed.
Bharat Heavy Electricals Limited - Tiruchirappalli

Boiler C&I
FSSS Oil gun start up timing sequence

THANK YOU

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