FSSS LOGIC SYSTEM

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Furnace Safeguard Supervisory System

Satisfactory Boiler start up Start up of individual oil system AB/CD/EF Operation of fuel firing subject to certain conditions A/B/C/D/F Protection and interlock of oil /Coal System

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Typical Graphic Display of fuel firing

244 subscriptions (requests) for data from the DPU. 75 maxSCRIPTS 30 Buttons

29 List Controls
3 Bar Charts 14 Text State controls

45 objects have dynamic borders

200K of various static bitmaps

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 The boiler can be placed in service, initially or after a Master Fuel Trip, in the following sequence through FSSS. Furnace Purge Before any fuel firing can takes place, initially or following a boiler trip, a satisfactory Purge Cycle

BOILER START- UP SEQUENCE

must be completed.

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 Initially, the Heavy Oil must be recirculated and

heated to obtain the proper temperature and viscosity for efficient combustion. After this is accomplished, the Heavy Oil Trip Valve (HOTV) can be closed and then the furnace purge

cycle can be started.

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 After the furnace purge cycle is completed, the heavy oil elevation (AB, CD, EF, & GH) can be taken into service. An oil elevation is said to be In Service, when at least three out of four heavy oil nozzle valves are open and the flame is sensed by the scanners. After the heavy oil elevation is in service, either of the adjacent coal elevation can be taken into service because Ignition Permit is now available for starting the pulverizer.

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 A Coal elevation is said to be In Service after the Pulverizer is ON, its Hot Air Gate (HAG) is open and the associated Feeder is proven (i.e., feeder ON for more than 50 seconds). A fireball

signal is established when the associated fireball

flame scanner senses flame and ELEVATION FLAME indicator is illuminated on the FSSS

console in control room.

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Unit start up sequence

Boiler purge operation Start up of oil firing(AB,CD,FH & GH) Adequate Ignition permit Firing of coal elevation(A,B,C,D,E,F,G & H) Flame sensing by scanners.

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FSSS LOGIC
FSSS logics can be broadly divided into 3 sections. Unit Logic. Oil Elevation Logic.

Coal Elevation Logic

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Unit logic
Boiler purge logic Master fuel trip logic Oil trip valve operation logic PA Fans logic Scanner air Fans logic Seal air Fan logic

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FURNACE PURGE
Purpose: : Complete Removal of unburnt fuel from entire furnace Procedure:
Ensure that all fuel to furnace is cut off and all flame is out Provide adequate air flow through furnace (30 to 40%) Initiate a MANDATORY purge time cycle (9 min)

Consequence:
Master Fuel Trip Relays are reset Firing of fuel into the furnace is allowed
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A. Unit Logic
Boiler purge logic, which ensures a

five minutes purge cycle is completed

before any fuel firing can take place. A Purge Ready signal at control room

will be available when all the following

conditions are satisfied:
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Boiler Purge Logic

All HFO nozzle valves are closed All Pulverizers are off No MFT condition present All feeders are off All scanners sensing no flame. All auxiliary air dampers modulating Both PA fans off All HAGs closed Air flow more than 30% and less than 50% HFO trip valve is closed Wind box to furnace DP is adequate.
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PURGE PERMISSIVES
All HFO nozzle valves closed All pulverisers OFF All feeders OFF No MFT condition present All scanners senses no flame All Auxiliary Air dampers modulating Both PA fans OFF All Mill HAGs closed Air flow more than 30% and less than 50% HFO trip valve is closed
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TO FSSS

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 MFT or Boiler Trip means: Complete isolation of all fuel to furnace under certain conditions Automatic Procedure: All oil valves are given closing command All mills and feeders are given trip command All Primary Air (PA) Fans are given trip command All Hot Air Gates (to mills) are given closing command Further Consequences: Turbine protection is initiated (to trip turbine) All SH and RH spray valves are given closing command All elevation SADC are given full open command Furnace pressure & Air flow controls are set to manual
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MASTER FUEL TRIP (MFT)

Master Fuel Trip Logic This ensures a safe shut down of the boiler in case of any abnormal conditions in boiler/ furnace. If some abnormal condition occurs, Master Fuel Trip Relay acts and ensures the closure of Heavy Oil Trip valve (HOTV) and all Oil Nozzle Valves (ONV), thus cutting off total oil supply. It also ensures the stopping of all pulverizer systems and Primary Air (PA) fans, cutting off total coal supply to boiler. The various abnormal operating conditions under which Master Fuel Trip occurs are as follows:-

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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.
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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 MFT RELAY

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
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Air flow less than 30% and boiler load not greater than 30%

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Unit Logic MFT consequences

Trips all mills Trips all feeders Trips PA fans Closes HFO trip valve Closes all elevation nozzle valves Close all HAGs

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Oil Trip Valve operation logic

This logic ensures that oil trip valve can be opened after the purge cycle is completed and no MFT condition is present, if the following conditions are also satisfied.

All nozzle valves are closed.

HFO supply pressure is satisfactory.

HFO header temperature is satisfactory.
Similarly, this logic ensures the closure of oil trip valve in case of MFT.
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Scanner air fans logic

It monitors the scanner air duct to furnace DP and ensures starting of scanner air fan - A or in case it fails to start, scanner air fan - B. This logic gives an open command to scanner fan outlet damper after starting the fan. Also, in case of both FD fans not running, it ensures the scanner air emergency damper is open.

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Seal air fans logic

Monitors seal air header to cold air duct DP and ensures the starting of seal air fan - A or B ( in case A does not start), provided at least one PA fan is running. Gives an open command to seal air fan discharge damper once fan starts.

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Oil Elevation Logic AB/CD/EF/HJ*

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Oil elevation logic

Start of oil elevations AB,CD,EF and GH Sequential operation with start command Corner1,corner3,corner2 and corner4 Gun advance,igniter advance Spark,atomizing valve open,oil valve open Sensing of discriminatory flame Retract of igniter

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Oil elevation logic

Stop of oil elevation Closure of oil valve,opening of scavenge valve Igniter advance and sparking Closure of atomizing valve and scavenge valve Retract of igniter and gun

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OIL ELEVATION LOGIC

There are four heavy oil elevations AB, CD, EF & GH. For all these elevations, logics are same. Oil elevation can be placed in service auto/manual. For a particular elevation, only one command is given for all the four corners together. (e.g. One common start command for elevation AB-1, 2, 3 and 4 guns). But start command goes to corners 1 to 4 sequentially. First command goes to corner 1; after 15 seconds start commend goes to corner 3; again after a lapse of 15 seconds start commend goes to corner 2; and again after a gap of 15 seconds start command goes to corner 4.
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A particular corner takes the start command only if the following conditions are satisfied: The particular corner oil gun engaged feedback is available. The steam scavenge valve is closed for the particular corner.

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The sequence of operation taking place for a particular oil gun once the command is given is as follows: First the oil gun is advanced. Once gun advanced feedback is available the HEA igniter is advanced. Then atomizing steam valve is opened for the particular corner. Then HFO nozzle valve gets open command. Spark command is given to igniter transformer, thus producing a spark at the spark tip. Then for this particular corner HFO flow satisfactory feedback comes from the flow switch in the oil line. The corner oil gun proves when the DISCR FLAME SCANNER senses FLAME. When 25 seconds elapses after oil valve open, igniter spark signal is removed and spark rod is retracted. If the corner oil gun did not prove FLAME by this time, Oil nozzle valve and atomizing steam valve closes. Gun and igniter are retracted.

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OIL FIRING PERMISSIVE-

1- PURGE COMPLETE/MFT RESET AND NO FIRST UP FAULT. 2- HFO PR. OK >25 KSC. 3- HFO TEMP OK >95C 4- IGNITOR AIR PR. >200 MMWG. 5- IGNITOR OIL PR. >10 KSC. 6- NO LIGHT UP IN PROGRESS. 7- NO BURNER START INHIBIT. 8-PERMISSIVE TO FIRE OIL.
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 OIL BURNER START LOGIC

*OIL

BURNER START PUSH BUTTON (NO OTHER OIL BURNER START IN PROGRESS).
OIL BURNER START SEQUENCE-

1-OIL BURNER SEC. AIR DAMPER OPENED. 2-OPEN IGNITER OIL MASTER TRIP VALVE. 3-NO FLAME SENSED IN LAST 5 SEC. 4-ENERGISE IGNITOR TRANSFORMER. 5- OPEN IGNITOR OIL SOLENOID V/V. 6- DETECT IGNITION OIL FLAME. 7- 4 WAY V/V TO FIRING POSITION. 8- OIL FLAME DETECTED. 24 May 2012 PMI Revision 9-CLOSE IOTV/SOL. V/V. 00

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Coal Elevation Logic A/B/C/D/F

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Coal elevation logic

Pulverizer start logic Availability of PA permit Availability of ignition permit Seal air /bowl differential pressure No MFT Lube oil pressure adequate Pulverizer stop logic

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Coal elevation logic

Feeder start logic Pulverizer on Outlet temperature adequate Speed demand minimum No MFT Feeder stop logic Had/cad logic

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COAL ELEVATION LOGIC

PULVERISER LOGIC This logic takes the count of total no. of pulverisers in service at any point of time, the no. of FD Fans and PA fans in service. With PA Fan ON and PA Header Pressure adequate (>560 mmwcl), it gives PA permit to start the Pulverizer. In case of PA Header Pressure going low-low or PA/ FD fans trips, it ensures the shut down of Pulverizers from top elevation to bottom elevation in a timed sequence.
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 Each mill can be taken in to service manually or automatically. Auto manual selection push button is available on FSSS console for each mill. Initially, Pulverizer Ignition Permit signal must

be established for the mill to start. Other condition

required to be established for starting the mill are as follows:-

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MILL PERMISSIVE:
30% BOILER LOAD AND
ADJACENT MILL FIRING
INTERMEDIATE OIL BURNER ELEVATION FIRING PA FAN IN SERVICE

OR
AND

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 Mill lub oil pressure adequate.

Start permit from FSSS. Mill Discharge valve open.

Mill outlet temp. > 93OC.(200OF)

Cold Air Gate (CAG) open. Tramp iron vale (Top Reject Gate) open.

Feeder inlet gate open.

Seal air DP adequate (200 mmwcl). Feeder local switch in remote.

Once the mill is ON, associated HAG can be opened and feeder can be placed in service.
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OIL BURNER FIRING ON MILL BEING BROUGHT INTO SERVICE1-AT LEAST THREE OIL BURNER S FIRING IN SELECTED ELEVATION. 2- (A) BOILER LOAD > 30% BCMR (B) UPPER OR LOWER ADJACENT COAL BURNER IN OPERATION

FOR ANY MILLS(A,B,C,D,E,F,G,H)

AND

EXAMPLE: FOR MILL A START PERMISSIVE:

1- ELEVATION AB 3/4 OIL BURNER FIRING. 2- MILL B FIRING
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OR

BOILER LOAD >30% BCMR.

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AND

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(A) AT LEAST 3 OIL BURNERS FIRING IN THE BURNER GROUP ABOVE (B) ADJACENT COAL BURNER ABOVE IN OPERATION (C) THIS ELEVATION IS HIGHEST IN THE BURNER GROUP. EXAMPLE- FOR MILL B START PERMISSIVE(1) ELEVATION AB 3 / 4 OIL BURNER ARE I/ S . (2) MILL A FIRING OR MILL C FIRING BOILER LOAD > 30% OF BCMR. (3) MILL C FIRING ELEVATION CD 3 / 4 OIL BURNER ARE I/S.

FOR B,D,F MILL

AND

AND

OR

AND

OR

AND

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(A) AT LEAST 3 OIL BURNER FIRING IN THE BURNER GROUP BELOW. (B) ADJACENT COAL BURNER BELOW IN OPERATION. (C) THIS ELEVATION IS LOWEST IN THE BURNER GROUP.

FOR MILL C,E,G

AND AND

EXAMPLE- FOR MILL C START PERMISSIVE

(1) ELEVATION CD 3 / 4 OIL BURNER I/S. (2) MILL B FIRING OR MILL D FIRING LOAD > 30% OF BCMR. (3) MILL B FIRING

OR

AND OR

ELEVATION AB 3 / 4 OIL BURNER ARE I/S. * NOTE THAT C ELEVATION IS LOWEST IN THE BURNER GROUP CD
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AND

MILL PERMISSIVE:
30% BOILER LOAD AND
ADJACENT MILL FIRING
INTERMEDIATE OIL BURNER ELEVATION FIRING

OR
AND

PA FAN IN SERVICE
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PARTIAL FLAME FAILURE

IT WILL NEVER OCCUR FOR THE FOLLOWING CONDITION(1) IF THREE OR MORE MILLS FIRING THEN PARTIAL FLAME FAILURE WILL NEVER EXISTS. (2) IF LESS THAN THREE MILLS ARE FIRING THEN PARTIAL FLAME FAILURE DOES NOT EXISTS IF MILL WHICH IS FIRING HAVE THE MILL PERMISSIVE FOR FIRING. IT WILL OCCUR WHEN THIS LOGIC SATISFY-

<3 MILLS FIRING

ANY MILL GROUP TRIP

MILL FIRING WITHOUT PERMISSIVE

AND
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VOTING OF ELEVATION
VOTING IN AB ELEVATION WILL BE AVAILABLE (1) MILL A FEEDER OR MILL B FEEDER I/S. AND ELEVATION AB 2 / 4 FLAMES IN. INTRLOCKED WITH ( ALL BURNER IN AB ELEVATION SATISFACTORY S/D OR 3 / 4 OIL BURNER IN THAT ELEVATION ARE I/S.) (2) VOTING IN BC ELEVATION WILL BE AVAILABLEMILL B FEEDER OR MILL C FEEDER I/S. AND ELEVATION B 2 / 4 FLAMES IN. (1) BOTH FEEDERS ON BURNER ELEVATION ARE NOT I/S. OR (2) 2/4 FLAME ARE NOT SENSED INTERLOCKED WITH 3 / 4 OIL BURNER ARE NOT FIRING. OR (3) OIL GUN IN THAT ELEVATION NOT SATISFACTORLY SHUTDOWN INTROLOCKED WITH 3 / 4 OIL BURNER IN THAT ELEVATION NOT FIRING. PMI Revision 00 24 May 2012

VOTING WIL NOT BE AVAILABLE

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Feeder start Logic

Feeder start command is given from FSSS

Elevation
service.

Logic
Feeder

only.
speed

This

command

is

continuously required to keep the feeder in demand minimum,

Pulverizer ON, pulverizer outlet temp > 130OF,

HAG open and no MFT are the important conditions required to give the feeder start command from FSSS.
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 In case of pulveriser power high, bowl DP High or feeder OFF command, feeder speed demand is driven to minimum. Release feeder to Auto Signal is also coming from FSSS. All of the above conditions are present and feeder is not ON for more than 50 seconds, release

signal for auto is available.

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