Pulverized Coal Fired Boiler Startup

ProcedureBy

Ashvani ShuklaC&I

Reliance

Index• Startup Procedure of Boiler and

Auxiliaries1. Induced Draft Fan2. Forced Draft Fan3. Primary Air Fan4. Mills5. Coal Feeders6. Air Pre Heaters7. Burners

ID Fan• START PERMISSIVES• ID FAN REGULATING DAMPER MIN POSITION (< 10%)• ID FAN SCOOP MIN POSITION (< 10%)• ID FAN OUTLET GATE - FULL CLOSED• ID FAN INLET GATE - FULL CLOSED• LUBE OIL PRESSURE ADEQUATE (> 0.8 KG/CM2) [TAG - HNC11CP201]• ID FAN BEARING TEMP NOT HI (< 850 C)• MOTOR BEARING TEMP NOT HI (< 950 C)• MOTOR WINDING TEMP NOT HI (< 1050C, ALL 6)• ANY FLUE GAS PATH (A OR B) AVAILABLE• APH - A ELECTRIC OR AIR MOTOR ON• APH - A FLUE GAS INLET DAMPER & OUT LET GATE OPEN PATH - A AVAILABLE• ESP - A PASS OUT LET GATE OPEN• OR• APH - B ELECTRIC OR AIR MOTOR ON• APH - B FLUE GAS INLET DAMPER & OUT LET GATE OPEN PATH - B AVAILABLE• ESP - B PASS OUT LET GATE OPEN• HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)• 15 SEC TIMER SHOULD ELAPSE AFTER THE PREVIOUS START OF ANY HT MOTOR (BFP, ID, CWP)

• INTERLOCKS STAND BY LOP STARTS• IF FAN IS RUNNING AND LUB OIL HEADER PRESURE < 0.6 KSC (60 SEC TIME

DELAY) OR• IF FAN IS RUNNING AND RUNNING LOP TRIPS >1 SEC AND OTHER LOP IN STANDBY. ID FAN INLET AND OUTLET GATE WILL OPEN ON AUTO, IF • ID FAN IS RUNNING (60SEC DELAY) [IF OTHER FAN IS NOT RUNNING GATE WILL

OPEN IMMEDIATELY] OR • ID FAN A & B ARE NOT RUNNING. ID FAN INLET /OUTLET GATE CLOSE PERMISSIVE WILL BE AVAILABLE ONLY WHEN

FAN NOT RUNNING. ID FAN INLET/OUTLET GATE CLOSE ON AUTO IF ID FAN TRIPS AND OTHER ID FAN IS

RUNNING & ONE FD FAN IN SERVICE. AFTER START COMMAND • OUTLET & INLET GATE CLOSE, IGV & SCOOP GO FOR MINIMUM FOR SELECTED

FAN • SELECTED FAN MOTOR STARTS • OUTLET & INLET GATE CLOSE, IGV & SCOOP GO FOR MINIMUM FOR STAND BY

FAN IF IT IS NOT IN SERVICE • OUTLET GATE OPENS & THEN INLET GATE OPENS FOR THE STARTED FAN. RUNBACK ON ONE ID FAN TRIPPING IS 90MW.

PROTECTIONS

S.N. DESCRIPTIONVALUES TIME

R(SEC)ALARM TRIP

1. 1 ID FAN BRG TEMP (DE & NDE) 0C 60 75 85 5

1. 2 ID FAN MOTOR BRG TEMP (DE & NDE) 0C 60 85 95 5

1. 3 ID FAN BRG VIBRATION (MM/SEC) 0.5 4.5 -

-1. 4 MOTOR BRG VIBRATION

(MM/SEC) 0.5 4.5 -

1. 4 LUBE OIL PRESSURE (KG/CM2)[HNC11CP205] 1.0 0.4 0.2 10

1. 6 H/C COOLER OIL I/L TEMP (0C)[HNC12CT201] 95 100 110 -

1. 7 H/C COOLER OIL O/L TEMP (0C)[HNC12CT202] 70 80 90 -

1. 8 ID FAN MTR WDG TEMP (0C) [2 / 6] 80 105 120 5

1. 9H/C LUBE OIL PRESSURE (KG/CM2)[HNC22/11CP201-4]

1.0 0.8 0.615

DURING STARTIN

G1. 10 H/C LUBE OIL FILTER DP

(KG/CM2) < 0.4 0.65 - HIGH0.7 - V HIGH - -

1. 11 POST PURGE FAN TRIP FROM BMS * - 10 + 75 -175 /

+150 -

ID Fan• ID & FD FANS WILL TRIP ON POST PURGE IF

FURNACE PRESSURE EXCEEDS > +150 OR < -175 MMWC AFTER PURGE COMPLETE AND BEFORE HFO TRIP VALVE OPENS.

• POST PURGE TRIP: AFTER 5 MINUTES OF PURGING, BOILER AIR FLOW > 40%, ALL FEEDERS & MILLS OFF, ALL OIL VALVES CLOSED, NO FLAME DETECTED, ALL GAS VALVES CLOSED, THEN BOTH ID FANS AND FD FANS WILL TRIP IF FURNACE PRESSURE VERY HIGH OR VERY LOW OCCURS

• CONSCUTIVE START TIMER WILL RESET TO ZERO WHEN ALL 6 WINDING TEMPERATURE < 500C & BREAKER STOP > 2 HOURS.

FD FAN

• START PERMISSIVES

• LUB OIL PRESSURE > 0.8 KSC• CONTROL OIL PRESSURE > 8.0 KSC• BLADE PITCH AT MINIMUM POSITION (<10%)• OUT LET DAMPER CLOSED• FAN BEARING TEMPERATURE NOT HIGH (<850C)• MOTOR BEARING TEMPERATURE (DE/NDE) NOT HIGH (<850C)• MOTOR WINDING TEMPERATURE (<1050C)• ANY ID FAN IS RUNNING & OTHER FD FAN IS OFF• (SECOND FD FAN WILL START ONLY IF BOTH ID FANS ARE RUNNING)• HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)

Sr.N. DESCRIPTIONVALUE TIMER

(SEC)ALARM TRIP

1. 1 MOTOR WINDING TEMPERATURE (0C) [2 / 6] 80 105 120 5

1. 2 FD FAN & MOTOR BRG TEMP (DE & NDE) 0C 60 85 95 5

1. 3 FAN BRG VIBRATION (MM/SEC) 0.5 4.5 --1. 4 MOTOR BRG VIBRATION

(MM/SEC) 0.5 4.5 -

1. 5 POST PURGE FAN TRIP FROM BMS - 10 + 75

-175 /

+150

-

1. 6 BOTH ID FANS OFF / TRIP FROM FSSS

PROTECTION

PA FAN• PERMISSIVE• PA FAN LUBE OIL PRESSURE ADEQUATE (> 0.8 KSC) [HFE11CP201]• H/C SCOOP MIN. POSITION (< 5%)• FAN INLET REGULATING DAMPER MIN. POSITION (< 5%)• FAN OUTLET DAMPER FULL CLOSE • MOTOR BEARING TEMP. (DE & NDE) NOT HIGH (< 85OC)• FAN BEARING TEMP. (DE & NDE) NOT HIGH (< 75OC)• ALL MOTOR WINDING TEMP. NOT HIGH (< 105OC)• PURGE COMPLETED• ANY FD FAN IS RUNNING.• HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)• WINDING TEMP NOT HIGH AND BOTH APH PATH ARE I/S• APH-A ON• APH-A PA I/L & O/L DAMPER FULL OPEN AND APH-B ON• APH-B PA I/L & O/L DAMPER FULL OPEN OR [ANY APH ON AND OTHER PA FAN NOT I/S]

INTERLOCKSAFTER GIVING START COMMAND TO PA FAN• FAN MOTOR STARTS.• OUT LET DAMPER OF STARTED FAN OPENS AFTER 60 SECONDS (IF DAMPER IN

AUTO)STAND BY LOP OF PA FAN STARTS• IF FAN IS RUNNING AND LUB OIL PRESURE < 0.6 KSC (60 SEC TIME DELAY) OR• IF FAN IS RUNNING AND RUNNING LOP TRIPS.SECOND SEAL AIR FAN WILL START AUTOMATICALLY• IF ANY PA FAN IS RUNNING AND SEAL AIR TO COLD PA DP IS LOW (< 100 MMWC)

FOR 10 SEC. AND SEAL AIR FAN NOT RED TAGGED AND OUT OF SERVICE IS NOT ALARM NOT PERSISTING OR

• FIRST SEAL AIR FAN FAILED TO START AFTER A START COMMANDSEAL AIR FAN (S) WILL STOP ON ANY OF FOLLOWING CONDITIONS• BOTH PA FANS NOT RUNNING FOR 15 SEC.• BOTH SEAL AIR FANS RUNNING AND SEAL AIR TO COLD PA DP NOT LOW AND

COMMAND GIVEN FOR STOPPING.

PROTECTIONSr.N. DESCRIPTION

VALUES TIMER(SEC)ALARM TRIP

1. 1 LUB OIL PRESSURE (KSC) [HFE11CP205] >1.0 0.4 0.2 2 SEC

1. 2 MOTOR BEARING TEMP. (DE & NDE) (OC) 50-60 85 95 5

1. 3 FAN BEARING TEMP. (DE & NDE) OC 40-50 65 75 5

1. 4 FAN BEARING VIBRATION (MM/SEC) 1.0 4.5 --

1. 5 MOTOR BEARING VIBRATION (MM/SEC) 1.0 4.5 -

1. 6 MOTOR WINDING TEMP (OC) [2 / 6] 80 105 120 5 SEC

1. 7 H/C WORKING OIL COOLER I/L TEMP. (OC) [HFE12CT201-3] <95 100 110 2 SEC

1. 8 H/C WORKING OIL COOLER O/L TEMP (OC) [HFE12CT202-3] <70 80 90 2 SEC

1. 9 H/C LUB OIL PRESSURE (KSC) [HFE12CP201-4] >1.0 <0.8 0.6

15DURIN

G STARTI

NG

1. 10 H/C LUBE OIL FILTER DP (KG/CM2) < 0.40.4 - HIGH

0.6 - V HIGH

- -

1. 11 BOILER TRIP FROM FSSS - - TRIP -

BOWL MILL• PERMISSIVESBOTH PA FANS RUNNING OR ONE PA FAN RUNNING AND NO MILL IN SERVICE.IGNITION ENERGY AVAILABLE• AT LEAST 3 OIL GUNS IN SERVICE AT THE ADJACENT OIL ELEVATION OR • ADJACENT COAL FEEDER SPEED > 50% & FEEDER RUN FOR 50 SEC AND BOILER LOAD > 30 %• BOILER LOAD > 30% AND MORE THAN 2 X1 ELEVATION BURNERS IN SERVICE (ONLY FOR

MILL-A)LUBE OIL OK• LUBE OIL PRESSURE ADEQUATE (> 2.4 KSC) FOR 5 MIN CONTINUOUSLY• OIL FILTER CLEAN (DP < 1.0 KSC)• LUBE OIL LEVEL ADEQUATE• SUMP OIL TEMPERATURE ADEQUATE (>22 0C)PULVERIZER OUT LET TEMPERATURE < 940 C WITH GOOD QUALITY SIGNALMILL INERTING STEAM VALVE CLOSED AND BREAKER NOT IN TEST.ALL MILL DISCHARGE VALVE & BURNER MANUAL ISOLATION VALVE OPEN (FORCED)TRAMP IRON HOPPER VALVE OPEN (FORCED).PULVERIZER BREAKER & GRAVIMETRIC FEEDER IN REMOTE.COLD AIR GATE OPEN (FORCED).

FURNACE FIRING PERMISSIVE SATISFIED. • SCANNER FAN AC OR DC RUNNING• ALL BURNER TILT AT HORIZONTAL OR ANY OIL ELEVATION IN SERVICE• PURGE COMPLETE• BOTH MFT RELAY RESET• NO FURNACE FIRING INHIBIT SIGNAL• NO COAL/OIL/GAS/IGNITOR ELEVATION BURNERS TRIPPED PERSISTING.HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)MILL TRIP RESET.SLAVE QUALITY O.KACFS ELEVATION A / B / C NOT SELECTEDACFS MDV / MMV / PAV / CIV STATUS O.K (FORCED)PULVERIZER NOT RED TAGGEDSEAL AIR VALVE OPENPULVERIZER TO SEAL AIR DP > 200mmwcMOTOR FEEDER NOT FAULTYSTART PULV SEQUENCE COMMAND GIVEN

INTERLOCKS• IF ANY PA FAN TRIPS TOP ELEVATION MILL WILL TRIP DIRECTLY • LUB OIL PUMP WILL START ONLY IF SUMP LEVEL IS ADEQUATE & OIL

TEMPERATURE IS >15 0C

• HOT AIR DAMPER WILL OPEN BY 10% ON HOT AIR GATE OPENING.

• WHEN MILL IS STOPPED, COLD AIR DAMPER WILL GO FOR 5% OUTTRACK OPEN & IF MILL SEAL AIR VALVE IS CLOSED COLD AIR DAMPER WILL CLOSE COMPLETELY.

• MILL AIR FLOW DEPENDS ON FEEDER SPEED:

• FOR FEED RATE 0-33% AIR FLOW WILL BE 27.6 TPH & FOR FEED RATE 33%-100% AIR FLOW WILL BE 27.6TPH TO 36 TPH LINEAR

• IF DUST IS IN SERVICE, 40% OF DUST FEEDRATE WILL BE ADDED WITH FEEDER FEED RATE AND AIR FLOW WILL BE AS GIVEN ABOVE

SLNO DESCRIPTIONVALUES TIMER

(SEC)ALARM TRIP1. 1 LUB OIL PRESSURE LOW > 2.4 1.2 0.75 101. 2 LUB OIL FILTER DP HIGH < 0.5 0.6 - 21. 3 LUB OIL TEMPERATURE HIGH (0C) 45 65 - 21. 4 LUB OIL TEMPERATURE LOW (0C) 20 - 21. 5 LUB OIL SUMP TEMPERATURE HIGH (0C) 40 - 52 21. 6 LUB OIL SUMP LEVEL LOW - - TRIP 101. 7 LUB OIL PUMP NOT RUNNING - - TRIP 21. 8 FEEDER I/S AND LOSS OF PA FLOW (T/HR) > 28 - 10 NO TD1. 9 IGNITION ENERGY NOT AVAILABLE

(REFER INTERLOCK) - - TRIP 51. 10 MFT ACTED - - TRIP -1. 11 MILL DISCHARGE GATES CLOSE (BYPASSED) - - TRIP 21. 12 SEAL AIR TO MILL DP LOW (MMWC) 300 - 125 60

1. 13 LOSS OF PA FAN / PRESSURE TRIP850 675 500 -

625 5BOTH PA FANS

STOPPED AND ANY ONE MILL RUNNING

TRIP -

1. 14 PA HEADER PRESSURE LOW TRIP(PA HDR PR < 675 mmwc AND ALL MILL I/S)

MILL-C TRIP 5 SEC

1. 15 BURNER MANUAL ISOLATION VALVE CLOSED (BYPASSED) - - TRIP -

1. 16FD OR BFP TRIPPING RUNBACK:ALL MILLS RUNNING AND (ONE FD FAN RUNNING OR ATLEAST TWO BFP’s NOT RUNNING)

- - MILL-C

1. 17 EMERGENCY PB OPERATED TRIP

1. 18 LOSS OF PA FAN RUNBACK TRIP IF 3 MILLS I/S MILL-C -MILL-B 2 SEC

IF MILLS-AB/AC/BC I/S TOP MILL -

1. 19LOSS OF PULVERIZER TRIP(FEEDER RUNNING AND PULV STOPPED/ RUNNING FB LOST)

TRIP 1 SEC

TOP MILL TRIPPING ON GEN BKR OPEN SIGNAL:TOP MILL WILL TRIP IF (GEN ACTIVE POWER > 3 MW AND

GEN BREAKER OPEN (10 SEC PULSE))AND ANY OF THE FOLLOWING CONDITION EXISTS• ANY TWO MILLS RUNNING AND 2 ELEVATIONS IN

SERVICE• 3 MILLS IN SERVICE AND NO COREX IN SERVICE• 3 MILLS IN SERVICE AND COREX X1 ELEVATION IN

SERVICE

LOS PANEL LOGICS

LUB OIL PUMP WILL START IF ALL THE FOLLOWING CONDITIONS ARE SATISFIED:• LUB OIL LEVEL ADEQUATE (TD 10SEC)• SUMP OIL TEMP ADEQUATE 15OC• LOP START (LOCAL SWITCH OR LOP START PB FROM BMS)-BYPASSED LUB OIL PUMP WILL STOP IF PULVERISER IS OFF FOR MORE THAN 5 MINUTES AND NO

CONTACT OF CRL34 EXISTS AND ANY OF THE FOLLOWING CONDITIONS ARE SATISFIED: • LUB OIL LEVEL VERY LOW (TD 10 SEC)• SUMP OIL TEMP NOT ADEQUATE• LOP ON AND LUB OIL PRESSURE VERY LOW (TD 10 SEC) LUB OIL SYSTEM HEALTHY IF LOP IS ON AND ALL THE FOLLOWING CONDITIONS EXISTS: • LUB OIL PRESSURE NOT VERY LOW 1.2 KSC (TD 60 SEC)• SUMP OIL TEMP ADEQUATE 15 OC• LUB OIL LEVEL ADEQUATE (TD 10 SEC)• LUB OIL DISCHARGE FILTER CLEAR 0.6 KSC LUB OIL SYSTEM FAILED IF ANY OF THE FOLLOWING CONDITIONS EXISTS:• IF PULVERISER IS ON AND• LOP NOT ON FOR 2 SEC OR SUMP OIL TEMP NOT ADEQUATE (TD 1 HOUR)• LOSS OF A.C POWER AT PLOS PANEL FOR > 2 SEC• LUB OIL LEVEL VERY LOW (TD 10 SEC)• LOP ON AND LUB OIL PRESSURE VERY LOW (TD 10 SEC)

RAW COAL FEEDER

• PERMISSIVES• MILL RUNNING (30 SEC TIME DELAY)• FEEDER SPEED DEMAND AT MINIMUM AND FEEDER NOT RT• FEEDER IN REMOTE• COAL FIRING PERMISSIVE SATISFIED• PA FLOW ABOVE MINIMUM >10 T/Hr• BUNKER OUTLET GATE OPEN• FEEDER INLET GATE OPEN• FEEDER TRIP RESET• MILL MOTOR NOT OVER LOADED• MILL GROUP READY AND GROUP SEQUENCE STARTED• IF MILL GROUP SEQUENCE IN AUTO AND FEEDER IN AUTO AND HOT AIR GATE

OPEN• NO BOILER TRIP

PROTECTION• LOSS OF COAL ON BELT (TIME DELAY 5 SEC.)• SHEAR PIN FAIL• MFT ACTED• MILL MAIN MOTOR OFF

6.0 - AIR PRE HEATER PERMISSIVE (ELE / AIR MOTOR)• APH GUIDE BEARING TEMP NOT HIGH (<700C)• APH SUPPORT BEARING TEMP NOT HIGH (<700C)INTERLOCKS• AIR MOTOR STARTS (SOLENOID VALVE DE-ENERGISES) WHEN ELE. MOTOR TRIPS.• AIR MOTOR STOPS (SOLENOID VALVE ENERGISES) WHEN ELECTRICAL MOTOR

STARTS.• SUPPORT / GUIDE BRG LOP STARTS WHEN APH ELEC MOTOR / AIR MOTOR ON

AND APH GUIDE / SUPPORT BRG TEMP > 400C• SUPPORT / GUIDE BRG LOP STOPS WHEN APH BRG TEMP < 400C• STAND BY LOP WILL START WHEN AUTO START COMMAND IS PERSISTING FOR

MAIN LOP FOR 2 SEC. AND THE MAIN LOP IS NOT ON OR IF THE RUNNING LOP TRIPS

AIR PRE-HEATER DAMPERSFLUEGAS, SA & PA INLET/OUTLET DAMPER • AUTO OPEN• APH ELECTRIC / AIR MOTOR NOT ON AND OTHER APH ELECTRIC / AIR MOTOR NOT ON• AUTO CLOSE • APH ELECTRIC / AIR MOTOR NOT ON AND OTHER APH ELECTRIC / AIR MOTOR ON• OPERATION OF INLET & OUTLET DAMPERS OF APH (FOR AIR

& FLUE GAS PATH) • FAN SIDE DAMPER SHOULD BE OPEN, FOR OPENING THE

BOILER SIDE DAMPER• BOILER SIDE DAMPER SHOULD BE CLOSED FOR CLOSING FAN

SIDE DAMPER

BURNER MANAGEMENT SYSTEM PURGE PERMISSIVES• ALL NOZZLE VALVES, IGNITOR VALVES CLOSED.• LOTV, HOTV, COREX GAS TV & IGTV CLOSED.• ALL SCANNER SENSE NO FLAME (ALL ELEVATION ¾ SCANNERS SHOWS NO FLAME)• BC 2/4SCANNER FLAME NOT ON• AB 2/4SCANNER FLAME NOT ON• AX1 2/4SCANNER FLAME NOT ON• X1 2/4SCANNER FLAME NOT ON• X3 2/4SCANNER FLAME NOT ON• NO IGNITION FROM AX1 AND BC CORNERS• NO DISCRIMINTING SCANNER FLAME ON• ALL FEEDERS OFF• BOTH PA FANS OFF• MILLS A, B & C HOT AIR GATES CLOSED AND ACFS HOT AIR GATE CLOSED• IGNITOR GAS & COREX GAS VENT VALVES OPEN• ALL AUXLIARY DAMPERS MODULATING• ELEVATION A, B, C AND XX OUT OF FOUR ELEVATION >/=TWO ELEVATIONS SHOULD BE

MODULATING

• CC, BC, AB, AX1, X1, X2, X3 OUT SEVEN ELEVATIONS >/= FIVE ELEVATIONS SHOULD BE MODULATING• OR• ELEVATIONS A, B, C AND XX OUT OF FOUR ELEVATION >/=TWO ELEVATIONS CONTROL STATION OUT PUT

COMMAND SHOULD BE >8% • CC, BC, AB, AX1, X1, X2, X3 OUT SEVEN ELEVATIONS >/= FIVE ELEVATIONS CONTROL STATION OUT PUT

COMMAND SHOULD BE >8%

UNIT AIR FLOW GREATER THAN 40%(190 TPH)• NO BOILER TRIP• DRUM LEVEL VERY LOW FOR MORE THAN 5 SECONDS• DRUM LEVEL VERY HIGH FOR MORE THAN 10 SECONDS • FURNACE PRESSURE VERY LOW (2/3 LOGIC)• FURNACE PRESSURE VERY HIGH (2/3 LOGIC)• TOTAL AIR FLOW LESS THAN 40%• BOTH ID FANS OFF• BOTH FD FANS OFF• LOSS OF REHEATER PROTECTION• UNIT FLAME FAILURE TRIP• LOSS OF ALL FUEL TRIP• LOSS OF 220V DC MFT POWER, FOR MORE THAN 2 SEC.• CRITICAL I/O MODULE FAIL• EMERGENCY TRIP SWITCH ACTIVATED• SPARE MFT TRIP• 11.ANY ID FAN AND FD FAN RUNNING• 12.CRITICAL IN PUT /OUT PUT MODULES FOR OIL GAS AND COAL ARE IN GOOD QUALITY

FUEL OIL VALVES• PERMISSIVES• LOTV OPENS ONLY IF ALL THE FOLLOWING CONDITION PERSISTS• NO MFT ACTIVE• LFO SUPPLY PRESSURE ADEQUATE (HJF60CP101)>6 Ksc• ELEVATION AX1 ALL LFO VALVES CLOSED • LOTV TRIP CONDITIONS DOES NOT EXIST• LFO TRIP VALVES NOT RED TAGGED• LFO TRIP VALVE CLOSE FEED BACK EXIST• LFO BOTH HEADER PT’S NOT IN BADQUALITY• ATOMIZING AIR PT NOT IN BADQUALITY (HJN10CP101)• MODULE STATUS OK• HOTV OPENS ONLY IF ALL THE FOLLOWING CONDITION PERSISTS• NO MFT ACTIVE • HOTV CLOSED• ATOMIZING STEAM HEADER PT NOT BADQULITY• HFO HEADER PT’S NOT BAD QULITY• SLAVE MADULE STATUS OK• HO SUPPLY PRESSURE ADEQUATE >=8 Ksc (HJF40CP102)• ALL HO NOZZLE VALVES CLOSED • HO SUPPLY TEMPERATURE ADEQUATE >=100 DEG C (HJF30CT101)

• HO RETURN TRIP VALVE OPEN • HO TRIP VALVE CLOSE COMMAND NOT EXISTS• HOTV NOT RED TAGGEDHORV OPENS ONLY IF ALL FOLLOWING CONDITION PERSIST HO RETURN TRIP VALVE OPEN PUSHBUTTON PRESSED• ALL HO NOZZLE VALVES CLOSED IGNITOR TRIP VALVE OPENS ONLY IF THE FALLOWING CONDITIONS PERSISTNO MFT ACTIVE• IGTV IN CLOSE CONDTION• ALL IGNITOR VALVES OF AX1 AND BC CLOSED• IGNITOR GAS SUPPLY PRESSURE ADEQUATE>=0.75 KSC (SFA20CP101)• IGNITOR TRIP VALVE TRIP CONDITION NOT EXISTS• IGTV NOT RED TAGGED AND CLOSED • BOTH PRESSURE TRANSMITTERS ARE GOOD QUALITY• SLAVE MODULE GOOD QUALITY IGNITOR FIRING PERMISSIVE• AL TRIP CLEAR AND 1 MINUTE TIMED OUT• MFT RELAY RESET • IGTV OPEN• IGNITOR SUPPLY PRESSURE >MIN• IGNITOR SUPPLY PRESSURE <MAX• EITHER IGNITOR FAN RUNNING OR IGNITOR TO FURNACE DP NORMAL (>MIN

80MMWC)

• PROTECTIONSHOTV CLOSES IF ANY OF THE FOLLOWING CONDITION PERSISTS.• TEMPERATURE OF HFO IS VERY LOW (HJF40CT102)<=90 0C AND ALL HONV’S NOT CLOSED AND HO RTV

NOT OPENED• PRESSURE OF HFO IS VERY LOW (2.5 KSC)(HJF40CP102/3/4) AND ALL HONV NOT CLOSED INITIAL TIME

DELAY 32 SEC NORMAL TIME DELAY IS 2 SEC• ANY HONV NOT CLOSED ON NO FLAME DETECTED AFTER IGNITION PROVEN (TIME DELAY IS 20SEC) AND

ANY BURNER VALVE FAIL TO CLOSE• ATOMISING STEAM PRESSURE VERY LOW (3.0 KSC (HJF60CP101/2/3) & 5 SEC TIME DELAY) AND

ALLHONV NOT CLOSED AND NO HO ELEVATION IN START/STOP>90 SEC AND HORTV NOT OPEN, • MFT ACTS AND HFO RETURN TRIP VALVE NOT OPEN • VALVE FAILED TO OPEN WITH IN 10 SEC • VALVE FAILED TO CLOSE WITH IN 10 SEC• NO FAULT IN HOTV FACE PLATE• VALVE LIMIT SWITCH MISS MATCH• HO PRESSURE BAD QUALITY• ATOMIZING STEAM PT BAD QUALITY• LOSS OF UNIT LOGIC POWER SUPPLY

LOTV CLOSES IF ANY OF THE FOLLOWING CONDITION PERSISTS• LFO HEADER PRESSURE LOW (2.0 KSC) AFTER OPENING OF LOTV 32 SEC TIME DELAY• ATOMISING AIR PRESSURE VERY LOW TRIP (2.5 KSC & 5 SEC TIME DELAY), PROVIDED ANY OF LONV IS

OPEN AND ATOMIZING AIR PRESSURE LOW AND NO LFO ELEVATION IN START /STOP FOR >70 SEC• VALVE FAILED TO CLOSE WITH IN 10 SEC AFTER GIVING CLOSE COMMAND (LOTV TRIPPED)• VALVE FAILED TO OPEN WITH IN 10 SEC AFTER GIVING OPEN COMMAND (LOTV TRIPPED)• NO FAULT LOTV FACE PLATE

• ANY LONV NOT CLOSED ON NO FLAME DETECTED AFTER IGNITION PROVEN (TIME DELAY IS 20SEC AND ANY BURNER VALVE FAIL TO CLOSE)

• BOTH LFO HEADER PT’S BADQUALITY• BOTH ATOMINZING AIR PT BAD QUALITY• IGNITOR BURNER VALVE FAILED TO CLOSE MORE THAN 20 SEC AFTER FLAME FAILURE• LOSS OF UNIT LOGIC POWER SUPPLY• MFT ACTIVE IGNITOR TRIP VALVE LOGICIGNITOR TRIP VALVE CLOSES IF ANY OF THE FOLLOWING CONDITION EXISTS• BOILER TRIP (MFT)• IGNITOR GAS PRESSURE VERY LOW (0.2 KSC)(SFA20CP102) / HIGH (40 KSC)

(SFA20CP101) PROVIDED ANY OF IGNITOR BURNER VALVES NOT CLOSED FOR MORE THAN 2 SEC.

• IGNITOR BURNER VALVE AX1/BC FAILED TO CLOSE MORE THAN 20 SEC. AFTER SENSING NO FLAME AND ANY BURNER VALVE FAIL TO CLOSE

• VALVE FAILED TO OPEN WITH IN 10 SEC • VALVE FAILED TO CLOSE WITH IN 10 SEC• IGNITOR GAS PRESSURE TRANSMITTER BAD QUALITY • LOSS OF UNIT LOGIC POWER SUPPLYNO TIME DELAY IS THERE FOR IGNITOR HEADER VENT VALVE CLOSING AFTER TRIP VALVE

OPENINGFOR ALL OIL BURNERS, WHILE SCAVENGING IGNITOR VALVE OPEN TIME IS 45 SEC

OIL BURNER SEQUENCE.

ON START COMMAND FOR ANY PAIR • IGNITOR CORNER VALVE OPENS PROVIDED IGNITOR NO FLAME PERSIST AND IGNITOR

FIRING PERMISSIVE SATISFIED AND START COMMAND GIVEN.• PAIR START WILL INITIATE ELECTRIC SPARK FOR 10 SEC WITH IN 10 SEC IGNITOR HAS TO BE

PROVEN (IONIC FLAME MONITOR DETECTS THE FLAME AND IGNITOR FLOW IS ADEQUATE)• IF IGNITOR PROVEN, ATOMISING AIR / STEAM VALVE OPENS (2-3 SEC). THEN OIL VALVE

OPENS (2-3 SEC).• IF SCANNER SENSES FLAME BEFORE 70 SEC, GUN STABLISES.• IGNITOR STAYS FOR 70 SEC FROM INSTANT OF START COMMAND. • IGNITOR CORNER VAVLE STOP/CLOSE WILL BE INITIATED AFTER CORNER OIL NOZZLE VALVE

OPEN (BURNER START TRIAL COMPLETION) WITH 15 SEC TIME DELAY• IGNITOR IS ALSO BROUGHT DURING SCAVENGING OR THE ASSOCIATED ELEVATION

BURNERS HAVE PLANNED SHUT DOWN OR STOP COMMANDATOMIZING AIR/STEAM VALVE OPEN• LFO/HFO SELECTED• ASSOCIATED CORNER IGNITOR TRIAL TIME COMPLETED• OIL GUN ENGAGE• SCAVENGING VALVE SHOULD BE CLOSED CONDITION• START MEMORY PERSISTING

BURNER IN SERVICE WILL COME • LFO/HFO SELECTED• OIL START MEMORY.• ONCE OIL VALVE FULL OPENS AND 15 SEC ELAPSED AND WITH IN THIS PERIOD

OIL FLAME DETECTED FROM MAIN FLAME SCANNE UNIT FLAME FAILURE• THE PROTECTION GETS ARMED WHEN ANY OF THE FOLLOWING CONDITION

PERSISTS FOR > 2 SEC.• ANY COAL FEEDER PROVEN• AX1 OR BC OIL ELEVATION ¾ NOZZLE VALVES OPEN WITH HFO & HFO PRESSURE

> 4 KSC• COREX X1 (2/4) / X2 (3/4) / X3 (3/4) GAS BURNERS IN SERVICE AND COREX GAS

PRESSURE > 30% (100 MMWC)• WHEN ALL THE ELEVATIONS VOTED TOGETHER FOR NO FLAME FAILURE TRIP

OCCURS ELEVATION VOTING• ELEVATION C VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS • FEEDER C NOT PROVEN FOR > 2SEC OR SIGNAL BADQUALITY. AND BC ELEVATION

(3/4 NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQUALITY• BC ELEVATION 2/4 SCANNER SHOWS NO FLAME AND BC ELEVATION (3/4 NOZZLE

VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQULITY.

ELEVATION B VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS • FEEDER B NOT PROVEN FOR > 2 SEC OR SIGNAL BADQULITY. AND BC ELEVATION (¾ NOZZLE

VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQULITY• AB ELEVATION 2/4 SCANNER SHOWS NO FLAME AND ELEVATION BC 2/4 SCANNER SHOWS

NO FLAME AND BC ELEVATION (¾ NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQUALITY

ELEVATION A VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS • FEEDER A NOT PROVEN FOR >2 SEC OR SIGNAL BADQULITY. AND AX1 ELEVATION (¾ NOZZLE

VALVE NOT OPEN) OIL NOT IN SERVICE AND AX1 HFO SELECTED.• AB ELEVATION 2/4 SCANNER SHOWS NO FLAME AND ELEVATION AX1 2/4 SCANNERS SENSE

NO FLAME AND AX1 ELEVATION (¾ NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE. ELEVATION X1 VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS• ELEVATION X1 NOT IN SERVICE 2/4 AND AX1 ELEVATION (¾ NOZZLE VALVE NOT OPEN) OIL

NOT IN SERVICE OR SIGNAL BADQUALITY. • ELEVATION AX1 2/4 SCANNER SHOWS NO FLAME AND AX1 ELEVATION (¾ NOZZLE VALVE NOT

OPEN) OIL NOT IN SERVICE OR SIGNAL BADQUALITY AND X1 2/4 SCANNER SHOWS NO FLAME.

ELEVATION X2 VOTE WHEN ANY OF THE FOLLOWING CONDITION PERSISTS • X2 ELEVATION NOT IN SERVICE OR X1 ELEVATION 2/4 SCANNER SHOWS NO FLAME AND

ELEVATION X3 2/4 SCANNER SHOWS NO FLAME.ELEVATION X3 VOTE WHEN ANY OF THE FOLLOWING CONDITION PERSISTS• WHEN X3 2/4 SCANNER SHOWS NO FLAME OR X3 ELEVATION NOT IN SERVICE.•

LOSS OF ALL FUEL.• THE PROTECTION GETS ARMED WHEN ANY IGNITOR AT ANY ELEVATION GETS PROVEN.• BOILER WILL TRIP ON LOSS OF ALL FUEL WHEN ALL THE FOLLOWING CONDITION PERSISTS• ALL COREX NOZZELS VALVE CLOSED/TRIPPED • AX1 AND BC ELEVATION ALL HONV CLOSED/TRIPPED • ALL FEEDERS OFF/TRIPPED• AX1 ELEVATION ALL LONV CLOSED/TRIPPED • ALL IGNITOR VALVE CLOSED/TRIPPED OR IGTV NOT OPEN/TRIPPED

REHEATER PROTECTIONTHIS PROTECTION GETS ARMED, WHEN ANY OF THE FOLLOWING CONDITION EXISTS• ANY FEEDER PROVEN.• ANY COREX BURNER PROVEN• AX1>/=3/4 WITH HFO • AX1 4/4 WITH LFO +BC>/=1/4• BC >/= 3/4 WITH HFO• AX1= 2 WITH LFO +BC=/>1• AX1=/>1 WITH LFO+BC=/>2• AX1=/>1 WITH HFO+BC=/>2BOILER WILL TRIP ON THIS PROTECTION WHEN ANY OF THE FOLLOWING CONDITION PERSISTS FOR 10

SEC.• GCB OPENS AND HPBP CV < 2% OPEN.• BOTH LPBP CVS < 2% OPEN.• BOTH LPBP STOP VALVES CLOSED.• BOTH MAIN STEAM VALVES (BOILER) ARE CLOSED.

LESS THAN FIRE BALL & LOSS OF A.C. (NOT INCLUDED AT PRESENT)• BOILER WILL TRIP ON THIS PROTECTION WHEN ALL THE FOLLOWING

CONDITION PERSISTS• ANY ELEVATION (AX1, BC, A, B, C, X1, X2, X3) STARTED & LOSS OF AC

POWER FOR 2 SEC• ALL FEEDERS OFF • AX1 OR BC ELEVATION NOT IN SERVICE {ELEVATION IN SERVICE MEANS

¾ HFO NOZZLE VALVES OPEN AND HFO PRESSURE > 30%} IGNITOR AIR FAN • START PERMISSIVE• FAN NOT OUT OF SERVICE• FAN NOT RED TAGGED • IGNITOR TO FURNACE <75 MMWC• OTHER FAN FAIL TO START• OTHER FAN FAIL TO STOP• • STOP PERMISSIVE• IGNITOR TO FURNACE DP >75 MMWC AND OPERATOR STOP COMMAND• EMERGENCY STOP FROM LOCAL

SCANNER AIR FAN

• START PERMISSIVE• FAN NOT OUT OF SERVICE• SCANNER TO FURNACE DP<150MMWC• OTHER FAN FAIL TO START• • STOP PERMISSIVE• STOP FROM DCS AND F SCANNER TO FURNACE DP>150 MMWC • SCANNER FAN DISCHARGE PR LOW 230MMWC AND SCANNER TO FURNACE DP

LOW 220MMWC• SCANNER AIR FAN EMERGENCY DAMPER• OPEN PERMISSIVE• BOTH FD FANS OFF• CLOSE PERMISSIVE• ANY FD FAN RUNNING•

ADDITIONAL COAL FIRING SYSTEM (ACFS)

ACFS PAV’S PERMISSIVES. • ALL MDV’S CLOSED.• ALL BIV’S OPENED.• ADJACENT IGNITION ENERGY PROVEN.• ELEVATION SELECTED FOR ACFS.• FURNACE FIRING PERMISSIVE SATISFIED.• FD FAN RELEASE.• UNSELECTED ELEVATION PAV’S NOT OPEN.• ACFS COLD AIR GATE OPEN.

ACFS HOT AIR GATE PERMISSIVES: • ANY ONE-ELEVATION PAV’S FULL OPEN.• HOT AIR GATE CLOSED.• HOT AIR GATE NOT RED TAGGED.

ACFS CIV’S PERMISSIVES: • ALL PAV’S OPENED.

• UNSELECTED ELEVATION CIV’S FULL CLOSED.• ACFS PA FLOW ADEQUATE.• ACFS PA HEADER TEMP NOT HIGH.

ACFS COMPRESSOR PERMISSIVES:• • DIV-1 OPEN TO GROUP A/C.• CONVEYING GROUP TRIP RESET.• COMPRESSOR TROUBLE RESET.• DIV-A & B OPEN TO SELECTED ELEVATION.• ALL CIV’S OF SELECTED ELEVATION OPEN.• ANY ONE ELEVATION SELECTED FOR ACFS.• MFT RELAYS RESET.

• ACFS PS PUMP PERMISSIVES:• • COMPRESSOR RUNNING.• COMPRESSOR DISCHARGE PRESSURE ADEQUATE.• CONVEYING GROUP TRIP RESET.• PS PUMP DISCHARGE PRESSURE NOT VERY HIGH.•

ACFS RAL PERMISSIVES:• • PS PUMP RUNNING.• COMPRESSOR DISCHARGE PRESSURE ADEQUATE.• PS PUMP DISCHARGE PRESSURE NOT VERY HIGH.• CONVEYING GROUP TRIP RESET.•

ACFS BAG HOUSE FAN PERMISSIVES:ON STARTING OF ANY PS PUMP, BAG HOUSE BLOWER WILL START IN AUTO

AND CORRESPONDING KGV WILL OPEN AFTER 15 SEC OF BLOWER RUNNING.

BAG HOUSE BLOWER WILL STOP IN AUTO AFTER BOTH RAL STOPPING AND KGVS WILL CLOSE AFTER BLOWER STOP.

ACFS CONVEYING GROUP EMERGENCY TRIPS:

• LOSS OF COMPRESSOR TRIP.• LOSS OF ACFS PA FLOW TRIP.• ACFS SELECTED ELEVATION MDV OPEN TRIP.• ACFS SELECTED ELEVATION MMV OPEN TRIP [BYPASSED]• ACFS LOSS OF IGNITION ENERGY TRIP.• ACFS SELECTED ELEVATION DIV CLOSE TRIP.• ACFS LOSS OF PA FAN / PRESSURE TRIP.• BOILER TRIP – ACFS.• ACFS SLAVE BAD QUALITY TRIP.

SECONDARY AIR DAMPER CONTROL • WIND BOX DP (MMWC) CONTROL SET POINT WILL BE

GENERATED AS PER REQIREMENTDAMPER OPERATION:XX ELEVATION:• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS

PER ABOVE CURVE (TABLE)• CLOSE WHEN BOILER LOAD >30%AND X3 NO BURNERS

IN SERVICE• OPEN FULL WHEN WB TO FURNACE DP GOES >THAN

240MMWC AND RESET AT 175MMWC• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR

BOTH ID OFF)

AB ELEVATION:• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• CLOSE WHEN BOILER LOAD >30%AND MILL-A/ACFS PAV’S NOT OPEN FOR MILL-A AND

MILL-B/ACFS PAV’S NOT OPEN NOT OPEN FOR MILL-B• OPEN FULL WHEN WB TO FURNACE DP GOES >THAN 175MMWC AND RESET AT 125MMWC• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF) CC ELEVATION:• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• CLOSE WHEN BOILER LOAD >30%AND MILL- C NOT IN SERVICE /ACFS PAV’S NOT OPEN FOR

MILL-C• OPEN FULL WHEN WB TO FURNACE DP GOES >THAN 175MMWC AND RESET AT 125MMWC• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)X1 ELEVATION:• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• CLOSE WHEN BOILER LOAD >30% AND AX1, X1 AND X2 NO BURNERS IN SERVICE• OPENING PROPORTINAL TO COREX C-HEADER PRESSURE (180MMWC TO 600MMWC SADC

WILL OPERATE 30% TO 100%)WHEN X1 IN SERVICE• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)X2 ELEVATION:• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• CLOSE WHEN BOILER LOAD >30% AND AX1, X1AND X3 NO BURNERS IN SERVICE• OPENING PROPORTINAL TO COREX C-HEADER PRESSURE (180MMWC TO 600MMWC SADC

WILL OPERATE 30% TO 100%)WHEN X2 IN SERVICE• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)

X3 ELEVATION:• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• CLOSE WHEN BOILER LOAD >30% AND X2 AND X3 NO BURNERS IN SERVICE• OPENING PROPORTINAL TO COREX C-HEADER PRESSURE (180MMWC TO 600MMWC SADC WILL OPERATE

30% TO 100%)WHEN X3 IN SERVICE• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)• A ELEVATION:• MODULATE TO MAINTAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• OPENING PRAPORTIONAL TO ELEVATION FEED RATE FROM 20 TO 70%• CLOSE WHEN THE BOILER LOAD >30% AND AX1 AND A NOT IN SERVICE• OPENS FULL ON MFT • B ELEVATION:• MODULATE TO MAINTAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• OPENING PRAPORTIONAL TO ELEVATION FEED RATE FROM 20 TO 70%• CLOSE WHEN THE BOILER LOAD >30% AND BC OR B NOT IN SERVICE• OPENS FULL ON MFT • C ELEVATION:• MODULATE TO MAINTAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)• OPENING PRAPORTIONAL TO ELEVATION FEED RATE FROM 20 TO 70%• CLOSE WHEN THE BOILER LOAD >30% AND BC OR C NOT IN SERVICE• OPENS FULL ON MFT • • AFTER 40 SEC OF MFT ALL THE DAMPERS TO AUTOMATICALLY MODULATE TO MAINTAIN 40 MMWC WIND

BOX PRESSURE

Thank you