1

BHARAT HEAVY ELELCTRICALS LIMITED

HIGH PRESSURE BOILER PLANT TIRUCHIRAPPALLI-620 014.

Operation & Maintenance Manual of BHELSCAN FLAME SCANNER SYSTEM (BN10)

BHARAT HEAVY ELELCTRICALS LIMITED, HIGH PRESSURE BOILER PLANT (Controls and Instrumentation / Fossil Boilers), Tiruchirappalli - 620 014, INDIA
Phone: 91 (0431) 257 5218, 257 5027

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CONTENTS

Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 6.1 Section 6.2 Section 6.3 Section 6.4 Section 7 Section 8 Section 8.1 Section 8.2 Section 8.3 Section 8.4 Section 8.5 Section 8.6 Section 9 Section10 Section 10.1 Section 10.2 Section 10.3 Section 11

INTRODUCTION SYSTEM SPECIFICATION MECHANICAL COMPONENTS COOLING AIR REQUIREMENTS ELECTRICAL COMPONENTS DESCRIPTION OF MODULES FLAME PROCESSOR MODULE 2/4 OUTPUT MODULE POWER SUPPLY MODULE SCANNER HEAD ELECTRONICS COMMUNICATION INTERFACE INSTALLATION AND START UP PROCEDURES MECHANICAL COMPONENTS COOLING AIR ELECTRICAL COMPONENTS SYSTEM OPERATION TEST DIP SWITCH SETTING PROCEDURES CALIBRATION OF SCANNER HEAD ELECTRONICS FLAME SCANNER CABLE MAINTENANCE & TROUBLESHOOTING SCANNER HEAD FIBRE OPTIC CABLE ELECTRICAL COMPONENTS LIST OF FIGURES
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LIST OF FIGURES:
Figure-1 Figure-2 Figure-3 Figure-4 Figure-5 : Windbox arrangement showing Flame scanner system : Flame Scanner Guide pipe assembly : Flame scanner assembly with optical head : Collimeter lens with barrel assembly : Functional block diagram

Figure-6A : BHELSCAN - General arrangement Figure-6B : BHELSCAN - General arrangement Figure-6C : Schematic of processor motherboard Figure-7A : Block diagram of Flame processor Figure-7B : BHELSCAN Flame processor module Figure-8A : Block diagram of 2/4 output module Figure-8B : BHELSCAN 2/4 module Figure-9A : Block diagram of power supply Figure-9B : BHELSCAN Power supply module (Front view) Figure-9C : BHELSCAN Power supply module (Rear view) Figure-9D : Schematic of power supply motherboard Figure-10 : Block diagram of Scanner Head electronic module Figure-11A : Flame scanner interconnection diagram Figure-11B : TB wiring details (Front mounted TB version) Figure-11C : TB wiring details (Rear mounted TB version) Figure-11D : BHELSCAN TB arrangement (Rear mounting)

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Section 1 INTRODUCTION
The prime output of flame sensing The microcontroller based flame sensing system is designed primarily for use on coal fireball and stable oil flame ignited by high energy arc (HEA) ignitor. It senses the visible light given off by the flame and can recognize a coal/oil flame by its characteristic fluctuations. The system consists of a fibre-optic connected scanner head assembly and a chassis containing electronic signal processing modules. The scanner head system is called the two out of four flame ON for coal, when two or more than two coal flame in an elevation is detected and individual flame ON for oil. The output is represented by the positioning of a set of form C contacts (break before make). A current signal is also available to indicate the individual flame intensity corresponding to each corner. RS232C serial output is available for computer/DCS connectivity.

assy. is located at the boiler and the chassis with electronics is mounted in the control room. The chassis may be located up to 200 metre from the boiler. A shielded four-conductor cable sends power to the scanner head electronics and returns an electronic signal representing flame to the chassis. The scanner head assy. is normally installed wind in the wind box assembly to (Figure-1). Refer to the respective project box arrangement drawing determine the location of scanner head assy. in the system.

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Section 2 SYSTEM SPECIFICATION

Specifications BHELSCAN comes in two versions - one with terminal blocks for field interconnection fitted in the front; another with terminal blocks fitted in the back side. Version with TB fitted in the front is recommended for panels in which BHELSCAN rack assemblies fitted has only front doors and no back doors provision. Version with TB fitted in back is recommended for panels having back doors also. All other components are same for both versions.

Input signal Signal Processor

: 0 to 2mA AC from Head Electronics : 4 Microcontroller Modules for 1 elevation alarm

2/4 Processor : 2/4 logic detection & fault Programmable : Pull in, Pull out, Parameters Display Display mode selection Parameter setting Communication : Serial interface Enclosure : 19 Rack with 3U size cards : 4 x 8 bit DIP switch Flicker frequency for oil, Flicker frequency for coal : 2 digit LED display : By Push button

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Section 3 MECHANICAL COMPONENTS

The complete mechanical assembly is comprised of a stationary part, called the flame scanner guide pipe assembly and a removable part, called the flame scanner assembly.

COMPRESSED ZERO

TO

ITS TILT.

MINIMUM IF A

LENGTH WHEN THE WIND BOX IS AT (HORIZONTAL) GUIDE SCANNER PIPE IS FIELD-

INSTALLED, BE SURE IT IS MOUNTED IN THE SAME MANNER TO PREVENT DAMAGE TO THE FLEXIBLE HOSE AND CONNECTIONS WHEN THE NOZZLE IS TILTED THROUGH ITS RANGE. ANY RADIUS OF CURVATURE GREATER

3.1 Flame Scanner Guide Pipe Assembly

The flame scanner guide pipe assembly consists of a scanner head housing, a flexible metal hose, a rigid guide pipe section, a cooling air manifold and a cover plate.(Figure 2) Guides inside the housing center the scanner head and provide a uniform passage for the external cooling air. The end ring in the housing forms a mechanical stop for the scanner head. The flexible hose assembly and the flexible guide pipe adapt the scanner to the tilting of the wind box nozzle and angle mounting. and scanner head housing. CAUTION WHEN SCANNER ASSEMBLIES ARE SHOP-INSTALLED, THEY ARE MOUNTED WITH THE FLEXIBLE HOSE The flexible hose is brazed to the guide pipe

THAN 18-IN MAY BE UTILIZED AS LONG AS ITS CROSS SECTION IS CIRCULAR AND DOES NOT RESTRICT FREE MOVEMENT OF THE SCANNER HEAD WITHIN THE CURVED PORTION. The guide pipe is normally fixed in the wind box front by means of a packing gland. The cooling air manifold is screwed (NPT) onto the guide pipe. The cooling air manifold is drilled and tapped to accept a flexible hose connection at its cooling air inlet and has an opening for the flame scanner head assembly. The scanner opening must be closed with the cover plate when the assembly is removed for maintenance.

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3.2 Flame Scanner Assembly

The flame scanner assembly has four sections similar to those found on the flame scanner guide pipe. There is a flame scanner head assembly, flexible metal hose, rigid pipe and the scanner housing assembly. The flame scanner head assembly (Figure - 3 ) consists of the scanner head body, which contains the collimator tube and shield, the collimating lens and barrel, a mounting plate, a compression spring, one end of the fibre-optic and a plug. The fibre optic cable is installed in the flexible metal hose and rigid pipe sections. It transfers the visible light flame signal from the lens to the photodiode mounted in the scanner housing assembly. When the scanner assembly is inserted in the guide pipe, cooling air from the cooling air manifold enters the scanner housing through two holes. This air flows down the rigid pipe and flex metal hose to cool the fibre-optic cable. Air is discharged into the furnace through the scanner head body and collimator tube. No seal gaskets are required in the scanner head assembly because of the pressure differential between the cooling air inside the scanner and the furnace. There should be no

reason to disassemble the scanner head assembly, except to clean the collimator shield (see the Maintenance and Trouble shooting section of this manual). The scanner housing couples the flame scanner assembly to the guide pipe and signal. A weatherproof disconnect coupling is provided to conveniently connect external wiring. A hexagon adapter adapts the connector to a in. pipe thread. Sealtite flexible hose or a similar weatherproof conduit should be used between the disconnect coupling and the rigid conduit leading from the wind box assembly. The flame scanner head assembly can be assembled in the following manner : 1. Slip fit the collimator tube and shield assembly into the scanner head body and hold it in place with a single Allen head screw. Using spacers, position the shield on the collimator to a allow cooling air to flow through the head assembly. (Figure 4). contains the the electronics for conditioning fibre-optic-transmitted

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NOTE A wind box structure will sometimes restrict the location of the guide pipe scanner head housing. To permit the 4. scanner to see the flame, a prism may be installed in place of the collimator shield. Use care when placing the 5. scanner in the guide pipe to assure proper orientation of the scanner head assembly. 2. Thread the fibre-optic cable, which is normally coiled inside the scanner housing assembly, through the rigid pipe, flex metal hose and the scanner head body plug. Make sure the jam nut is in place on the cable before installing the compression spring and mounting plate. Then screw the collimating lens barrel onto the cable. 3. Lock the mounting plate to the lens barrel with the jam nut. Insert the lens barrel in the scanner head body until the mounting plate rests against the stop pins. Insert the compression spring and plug. Three socket head screws hold the plug in the scanner head body.

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Section 4 COOLING AIR REQUIREMENTS

The external cooling air passes through the guide pipe, the flexible hose and the annulus between the scanner head and housing. The air is discharged into the furnace at the top of the scanner head, thereby removing any heat picked up by the scanner from the hot combustion air. The scanner head should not be exposed to a continuous temperature above 300F without cooling air. NOTE When the scanner assembly housing adapter flange is disconnected, the scanner assembly must be removed from the guide pipe immediately. Wrap a cloth around the scanner support pipe and hold it firmly against the cooling air manifold to minimize the escape of cooling air while the head is being removed. The head should then be held in the rag to protect it from damage. Install the cover plate to retain the cooling air flow within the scanner guide pipe. This prevents a reduction of cooling air pressure at the remaining scanners. Cooling air flow requirements are (per scanner) 55 cfm at 120F (maximum temperature measured at the scanner air booster fan inlet). Air manifold pressure at the scanner guide pipe must be 150mmwc.(g). above furnace pressure for all operating conditions. After shutting down the unit, scanner cooling air must be maintained until furnace conditions are such that the scanner assembly cannot overheat. installed scanners. Shut off valves must not be in cooling air lines to the

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Section 5 ELECTRICAL COMPONENTS

The electrical components of the BHELSCAN system are contained in the scanner housing assemblies and the card rack assembly. A photo diode located in each scanner housing assembly converts visible light (flame signal) observed by the scanner head into an electrical equivalent signal. The electrical signal is conditioned by amplifiers located in the scanner housing assembly. The scanner housing displays intensity in percentage. Range is 0-100%. b) A fault signal is established if the intensity component is less than its minimum preset limit or greater than its maximum preset limit. If a fault signal is established, a fault LED is lit and flame signal cannot be established for that corner. Hence oil flame or coal flame lights will not come ON. c) When the value exceeds of intensity the field component

output signal is an AC current signal, which is sent to the card rack assembly for processing. Refer functional block diagram. ( Figure 5 ) In the card rack assembly, each current flame signal is converted into a voltage flame signal. The voltage flame The intensity signal is then separated into intensity and frequency components. component of the signal varies between no flame value (dark furnace) and a normal flame value based on the actual flame intensity. The frequency component of the signal is used to prove that an active flame exists. a) An intensity signal indicates the magnitude of the flame brightness. A 2 digit LED display in the front facia of flame scanner module

adjusted limits (pull in, pull out settings), an intensity light will come ON at the associated scanner channel. A flame signal will be established only if no fault (fault LED is OFF) signal exists and a predetermined component (frequency setting) is proven to exist. The frequency of the fire ball (coal flame) is normally lower than the frequency of the individual oil gun flame. Therefore, when at least 2 out of 4 scanner channels show coal flame, the system 2/4 flame light will come ON in the front facial of 2/4 module. If any scanner channel indicates a fault, the associated scanner channel fault LED frequency F1, F2

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will come along with the system fault LED and that channels flame output will be disabled. The 2/4 module gives 2 changeover contacts for 2/4 flame and one

changeover contact output for system fault. Description of the various modules are given in the following sections:

Section 6 DESCRIPTION OF MODULES

The flame scanner card rack assembly consists of the following modules: 1. 2. 3. Flame module 2/4 output module Power supply unit - 1 No. - 1 No. processor - 4 Nos. putting into its slots. The scanner head current signal (0 2.0 mA) enters flame processor module and is converted to voltage. The voltage is signal is normalized in signal conditioner such that, a high voltage represents the bright furnace and low voltage represents the dark furnace. This signal is divided into three The flame processor modules and 2/4 output module are mounted in processor motherboard, assembled in the card rack. Refer Schematic diagram of Processor mother board.( Figure 6C ) The power supply unit is mounted in the power supply motherboard, assembled in the card rack. The second and third signals are fed to frequency detection circuit. This circuit consists of an AC amplifier and a wave shaper. One output represents the coal flame fluctuation and the other output represents the oil flame fluctuation. The outputs are fed to microcontroller. The AC gain can be adjusted to suit the furnace This module is a standard euro card suitable for 19 rack assembly. Flame processor module is located in the slots 1 to 4 in the processor module. These modules can be interchanged within them. The set values can be verified before The +/-15 V DC and GND are extended to scanner head electronics
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Refer

BHELSCAN general arrangement

drawing. ( Figure 6A & 6B ) parts. One signal goes to intensity

monitoring circuit. This consists of a voltage amplifier and an ADC. The output of this ADC is connected to Microcontroller.

6.1 Flame Processor Module

(Refer block diagram Figure - 7A & 7B) :

flame condition independently for coal and oil flame flicker levels by RP1 and RP6 single turn potentiometers respectively.

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located at furnace front in the field from this module. There are two semiconductor fuses rated for 63mA are available in the flame processor motherboard to protect the DC supply to scanner head electronics. The removal of this module blocks the DC supply to field. DO NOT REMOVE ANY MODULE WITH POWER ON There are 4 DIP switches (each switch with 8 bits) are available to set the following data in binary form to the microcontroller. For DIP switch settings, refer DIP SWITCH SETTING PROCEDURE. a. Pull in value (typical value is 40%) b. Pull out value (typical value is 30%) c. Coal d. Oil frequency frequency set set value value (typical value is 5 Hz. ) (typical value is 30 Hz. ) - Adjustable at site. The front facia of this module consists of a 7-segment display, 9 status LEDs and one Push Button. Card pullers are available to remove the card from the rack. A mode PB can change the display mode to scroll the various values. The heart of the system is an 8-bit microcontroller. This receives the signals from ADC, wave shaping circuit, mode PB and DIPswitches. From these signals, the microcontroller decides the flame status

and energies the relay. Also, the status of flame1 and flame 2 and fault are transferred to the 2/4 output module. The microcontroller updates the display and LED status according to the input. The digital outputs of flame1 (coal) and flame2 (oil) status are fed to the 2/4 output module. A 4-20 mA current output is available to represents the intensity of the flame. This circuit consists of a DAC and current converter. Relay outputs are available in form of change over contact for flame 2(oil) output to use in BMS of boiler. For the location of DIP switches and AC gain potentiometers, refer Figure - 7B.

6.2 2/4 Output Module

(Refer block diagram Figure 8A & 8B ) :
This card is a standard euro card suitable for 19 rack assembly. This is located in the 5th slot of processor motherboard. The heart of the module is an 8-bit microcontroller. This receives digital signals corresponding to flame1 ON from all four flame processor modules. Whenever, two or more than two flame 1 (coal) inputs are available, this module gives output for 2/4 flame ON output. This indicates the presence of fireball. There

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are two relays available. One relay is for the 2/4 output of coal flame. The other relay is for fault alarm to DCS. RS232C serial communication circuit, transfer the flame parameters for all processor modules to computer on-line via serial port. Two sets of 2/4 output relay contacts are available at the terminal. These are changeover contacts. In the front facia, two status LEDs are available for 2/4 output indication and fault status. Refer Figure 8B for the location of 2/4 relay (Fireball flame ) and fault relay.

power supply motherboard to switch ON the AC power supply to this module. In the front facia, four status LEDs are available for presence of AC power ON, -15V DC ON, +15V DC ON and +5 V DC ON. All four LEDs should glow for the normal operation of flame scanner.

6.4 Scanner Head Electronics

(Refer figure 10 ) :
This is a circular module available inside the flame scanner head assembly. This is mounted at furnace front in the windbox. A special triple shielded flame scanner cable connects this module to respective flame processor module in the flame scanner card assembly at flame scanner panel located at remote control room. This module converts the light transmitted from the furnace flame. (via a fibre optic cable) to an electrical signal. Visible light from the flame strikes photo diode and is converted into a current signal. This current is linear function of illumination (intensity) and covers fivedecade range of lux. Photo diode signal is converted to log signal voltage in the temperature log amplifier to cover the entire range of intensity. Amplifier offset and gain adjustments are factory set

6.3 Power Supply Module

(Refer Figures - 9A, 9B, 9C & 9D ) :
This is a linear power supply suitable for 19 rack assembly. This is mounted in power supply motherboard. This will work in 110V AC or 230V AC as given in the nameplate. This is factory set. There are three DC outputs produced in this module. 1. +15 V DC @ 0.75 Amps maximum 2. 15V DC @ 0.25 Amps maximum 3. +5.0V DC @ 1.5 Amps maximum All the above DC outputs are over voltage and short circuit protected. There is a fuse available in the power supply motherboard, whose rating is 2 Amps. A DPDT toggle switch is provided in the

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through potentiometers R101, R103. This voltage signal is converted to current signal (0 2.0 mA) for transmission to flame processor module. A feedback LED is mounted in the photo diode holder, to avoid the saturation of log amplifier in the event of very low light

or dark furnace conditions. This feedback loop is the key circuit in the electronic fault detection scheme. The light emitted by the feedback LED is adjusted by R114 at potentiometer during calibration

laboratory / factory.

Section 7 COMMUNICATION INTERFACE

Serial communication (RS232C) a . Intensity set value b . Pull in set value C . Pull out set value D . Frequency 1 (coal) set value E . Frequency 2 (oil) set value F . Actual frequency of flame 1 (coal) G . Actual frequency of flame 2 (oil) H . Fault status i . Flame 1 status Load and run the PC2Scanner.exe programme supplied with the system. This program will display the following : Baud Rate Stop Bit Parity = = = 9600 1 No parity

output is provided in each BHELSCAN covering four corners of one elevation. Terminal block (TB5) in system mother board has 3 terminals viz. 10, 11, 12 for Transmit (Tx), Receive (Rx) and ground. Prepare a cable (2 pair twisted 0.5 Sq.mm shielded cable) with one side soldered to 9 pin D type connector suitable for inserting into COM1 or COM2 serial port of personal computer and connect the other side to these terminals. The 2/4 output module periodically interrupts each flame scanner and collect the following data. This data will be communicated via serial output approximately once in a second.

To select COM1 or COM2 (Enter 1 or 2) = Now enter the COM port Number 1 or 2 in which the communication cable is connected. Communication will be established and PC will display the following corresponding to 4 corners.

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FLAME SCANNER CORNER1 Actual Intensity Pull in set Pull out set Frequency 1 set Frequency 2 set Actual frequency 1 Actual frequency 2 Flame 1 Flame 2 The above table will be updated automatically every second approximately. CORNER2 CORNER3 CORNER4

Section 8 INSTALLATION AND START-UP PROCEDURES 8.1 Mechanical Components

Make sure the Safe Scan head assembly is properly inserted in the flame scanner guide pipe assembly and that sufficient clearance exists directly behind each guide pipe to allow easy removal. A weatherproof quick-disconnect electrical coupling (Figure 3) is provided for the external wiring. thread attachment. A hexagonal adapter Sealtite flexible hose provides for the connection of a -in. pipe or a similar weatherproof conduit should be used between the quick-disconnect CAUTION THE SCANNER HEADS MUST BE COOLED WHENEVER THERE IS A FIRE IN THE FURNACE OR THE BOILER INTERIOR IS ABOVE 300F. A COOLING AIR SYSTEM MUST BE PROVIDED AND CHECKED OUT BEFORE THE BOILER IS LIT OFF. coupling and the rigid conduit. The flexible hose should be long enough (4 or 5 ft) to withdraw the scanner from the guide pipe without disconnecting the coupling.

8.2 Cooling Air

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On balanced draft units, the cooling air for the scanners is frequently supplied by a separate fan and piped to the scanner cooling air manifolds. The scanner cooling air supply is taken from the forced draft (FD) fan discharge duct in combination with combustion air to the ignitors. In this case an emergency damper, a low air pressure switch, a high air pressure switch and a scanner fan are also provided. The scanner fan starts when the air pressure gets too low, usually at 6 in. w.g.

8.3 Electrical Components

Input and output connections to the flame scanner card rack assembly are to be done as per the Flame scanner interconnection diagram Figure 11A and as per the following table: (Also refer for detailed TB wiring, Figure 11B for front mounted TB version & Figures 11C & 11D for rear mounted TB version )

Power supply mother board Most air systems are supplied with air filters between the scanner fan and the cooling air manifold. A differential pressure gauges and switches to actuate an alarm are installed across the filter to provide information on filter condition. should be checked cleanliness. The emergency damper opens to admit ambient air to the system when the FD fans are out of service. All components should be checked for proper operation. Filters for TBP1 TBP1 2 3 periodically TB No. TBP1 Terminal DESCRIPTION No. 1 Phase (230V or 110V as given in the name plate) Neutral Earth

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Processor mother board TB No. TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB2 - Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB3- Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 Terminal No. 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common Flame-2 relay contact NC Current output negative Current output positive +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common Flame-2 relay contact NC Current output positive Current output negative +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common B+ BSIG GND Sh. NO COM NC II+ B+ BSIG GND Sh. NO COM NC II+ B+ BSIG GND Sh. NO COM DESCRIPTION MARKING

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TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB4 - Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5

8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12

Flame-2 relay contact NC Current output positive Current output negative +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common Flame-2 relay contact NC Current output positive Current output negative 2/4 flame contact NO 2/4 flame contact common 2/4 flame contact NC 2/4 flame contact NO 2/4 flame contact common 2/4 flame contact NC selectable System fault contact common No connection Transmit Receive Ground

NC II+ B+ BSIG GND Sh. NO COM NC II+ NO1 COM1 NC1 NO2 COM2 NC2

System fault contact NO/NC jumper NO/NC COM TX RX GND

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8.4 System Operation Test

After installation is completed, the following tests can be done to verify proper operation of the system: 1. At one channel, disconnect the signal wire from the terminal block. With the power switch in ON position, the intensity display should show input open by flashing 100%. The channel fault light should be ON and the system fault light in 2/4 module should be ON. 2. Reconnect the signal wire to the terminal block. The corner fault light now should be OFF. The system fault alarm light in 2/4 module should also go OFF if none of the other corners indicate fault. The intensity display should return to a normal indication. 3. Repeat step 1 & 2 for all channels. 4. During furnace OFF condition, the display corresponding to all corners shall show 00 to indicate the dark furnace condition. 5. If any power supply wire is cut or any short circuit in the signal wire to ground, then the display will show 00 flickering. check the The fault LED will glow. wire continuity. This Switch OFF the power supply and condition shall be set right, before proceeding further.

6. Whenever the power is switched ON, the display will show the intensity. The corresponding IN LED will glow. 7. The display mode can be changed by momentarily pressing and releasing the MODE PB (square PB). 8. The following display modes are available. 1. IN intensity 2. PI-Pull in set value of intensity 3. PO-Pull out set value of intensity 4. F1- coal frequency set value 5. F2-oil frequency set value 6. AF & F1- actual frequency of coal 7. AF & F2- actual frequency of oil 9. Select PI mode. The display should read the pull-in set value in %. Similarly, change the modes and verify the other values as shown from 8.2 to 8.5 above. 10. Press mode PB again momentarily. Now, LEDs corresponding to AF and F1 both will glow simultaneously. The display reads the actual coal frequency (F1). 11. Press mode PB again momentarily. Now, LEDs corresponding to AF and F2 both will glow simultaneously. The display reads the actual oil frequency (F2). 12. To change the set values of IN, PI, PO, F1 and F2 if needed, refer parameter setting procedures given above.

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13.

During boiler operation, the Flame1 LED in respective corner processor module will be ON when the following conditions are met.

e. f.

Oil frequency is less than F2 set value OR Any fault conditions exits. (Fault LED ON)

a. b. c.

Flame intensity is more than PI set value AND Coal frequency is more than F1 set value AND No Fault condition exists (Fault LED OFF) Flame1 LED will switch OFF, if any one of the following conditions is met.

15. 4-20 mA current output is available corresponding to 0 100% of flame intensity in respective corner at TB Nos. 9 & 10. If any fault condition exists, (Fault LED ON), this current output will go to 4 mA irrespective of the intensity level shown in display. 16. The 2/4 Flame LED indication in 2/4 flame module represents the presence of fireball during coal firing. This LED will be ON, whenever, two or more corners Flame1 (coal flame) show flame. The relay outputs in two sets of contacts are available at TB Nos.1,2&3 and 4,5 & 6 of TB5. 17. If any fault LED is ON in any of the processor modules, Fault LED in 2/4 module will be ON. The Fault relay will get energized. The relay output is available in TB Nos. 7&8 of TB5. 18. RS232-C serial communication output is available at TB Nos.10, 11 & 12 in TB5. This can be used to communicate the flame parameters to Personal Computer.

a. b. c. 14.

Flame intensity is less than PO set value OR Coal frequency is less than F1 set value OR Any fault conditions exits. (Fault LED ON) During boiler operation with oil, the Flame2 LED will be ON when the following conditions are met. The relay output is available at TB Nos. 6,7 & 8 in the respective corner.

a. b. c.

Flame intensity is more than PI set value AND Oil frequency is more than F2 set value AND No fault condition exists. (Fault LED OFF) Flame2 LED will switch OFF, if any one of the following conditions is met.

d.

Flame intensity is less than PO set value OR

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8.5 Dip Switch Setting Procedure

(Refer Figure 7B ) :
Switch OFF the power supply to BHELSCAN system. Remove the flame processor module at corner 1. Locate S1 DIP switch as shown in Figure 7B for intensity pull-in value. Set 40 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 ON 5 OFF 4 ON 3 OFF 2 1 OFF OFF

Locate S2 DIP switch as shown in Figure 7B for intensity pull-out value. Set 30 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF 5 ON 4 ON 3 ON 2 ON 1 OFF

Locate S3 DIP switch as shown in Figure 7B for coal frequency set value. Set 05 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF 5 OFF 4 3 2 OFF 1 ON OFF ON

Locate S4 DIP switch as shown in Figure 7B for oil frequency set value. Set 30 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF 5 ON 4 ON 3 ON 2 ON 1 OFF

For other values of above settings, convert the decimal value to 8 bit binary and set the DIP switches accordingly. For 1 status, the switch shall be in ON position. Repeat the same procedure for settings in other flame processor modules. Insert the modules into the respective location and switch ON the AC power supply. Verify the set values in individual flame processor module by selecting the display using mode PB.

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8.6 Calibration Head Electronics

of

Scanner

(DVM) between signal C and common D terminals on the electronics card; then reconnect the scanner cable. Turn the scanner power supply on and adjust potentiometer R101 to provide a reading of 0.000 V on the DVM. Replace the 1 mA dc current source with a 1 A source and adjust potentiometer R103 to provide a reading of 1.000 V on

The scanner head electronics are adjusted during manufacturing. If a component on the electronics card is replaced, field adjustment be required. of the gain and offset potentiometers and dark furnace bias will

8.6.1 Calibration Head Electronics

of

Scanner

the DVM.

Disconnect the scanner cable

and test leads, reconnect the photodiode and proceed with the dark furnace bias adjustment.

8.6.1 Gain and Offset Adjustment:

The flame scanner assembly must be removed from its guide pipe. Turn both power supplies off, disconnect the cable and open the head assembly for access to the scanner head electronics card. The following equipment will be required : a. b. c. d. Digital voltmeter (DVM) 1 mA dc current source (1 V dc in series with a resistor; 1k, 1/8W, 1%) 1 A dc current source (1V dc in series with a resistor; 1M, 1/8W, 1%) Small soldering pencil the positive lead of the

8.6.2 Dark Adjustment :

To ensure proper

Furnace

Bias

operation

of

the

BHELSCAN relatively uniform voltages must be input to the chassis by the four associated scanner assemblies during dark furnace, no fire conditions. Total absence of a signal from the scanner assembly would generate a fault condition. To prevent this from occurring, feedback LED is installed on the scanner head electronics card adjacent to photodiode. The flame scanner assembly should be removed from its guide pipe and the scanner cover plate should be installed. Completely block all light from the furnace end of the fibre-optic cable and open the scanner housing.

Disconnect

photodiode from its terminal.

Simulate a

photodiode input by connecting the 1 mA dc current source to the photodiode terminals. Connect the digital volt meter

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BHELSCAN O & M MANUAL

Connect a digital voltmeter (DVM) between the signal C and common D terminals on the electronics card. Reconnect the scanner cable to the scanner assembly. The power supply switch should be turned on. Work under a dark cloth to reduce he amount of ambient light admitted to the scanner head. Adjust potentiometer P114 so that the DVM reads

approximately 2.1V. scanner head

This completes the adjustments.

electronics

Disconnect the test leads, reassemble the scanner assembly and reinsert it in the guide pipe. All four scanner channels, under dark furnace conditions, should have a similar intensity meter reading.

Section 9 Flame Scanner Cable

This is a 1.3 sq.mm., Annealed, Tinned, Copper Conductor, Elastomeric/ material Thermoplastic/Equivalent Colour Code for Core/Pair :First Pair Red & Black This Pair is used to connect Power Supply to field. Second Pair Green & White This Pair is used to connect Signal to Amplifier.

Insulated, Twisted pair, Aluminium Backed Mylar Tape Shielded with Drain Wire, 2 such pairs laid up, Over all Aluminium Backed Mylar Tape Shielded with Drain Wire, Sheathed Cable. Elastomeric / Thermoplastic/Equivalent material Over all

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BHELSCAN O & M MANUAL

Section 10 - Maintenance And Trouble Shooting

10.1 Scanner Head :
The scanner head at the front of the fibre-optic scanner assembly has an opening for viewing the flame. build up and cover the opening. scanner head should be With The certain types of coal, slag may eventually inspected

10.1 Electrical components

The electronic modules do not require periodic maintenance. If trouble does occur, the best way to troubleshoot the system is to substitute modules in the card rack assembly and/or head electronic modules. Modules are to be inserted only in the slots designated for them. If the scanner chassis is not working, check whether lamps in the power supply module corresponding to AC power ON, -15V ON, +15V ON and +5V ON. If AC power is not ON, check the fuse F01 in the power supply mother board and the incoming AC power. If the DC supplies are not ON, check the corresponding fuses at the rear side of the power supply module. If the fuses are alright and still any one of the above DC voltages are not present, power supply module has to be replaced. In flame processor module, fault lamp should be OFF. If this lamp is ON, check the fuses corresponding to +15V and 15V feeding to head electronics in the processor mother board. If the fuses are healthy, then check the continuity of

periodically and cleaned, if necessary. Hence, an inspection program should be established experience. based on operating

10.1 Fibre optic cable

The collimator shield and the lens on the end of the fibre-optic cable should also be inspected periodically for cleanliness. operating inspection established, The degree of fouling will characteristics program based and should on the An be

depend on the type of fuel used, the plant cleanliness of the cooling air.

operating

experience. Always check the shield and lens when the scanner head is inspected.

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BHELSCAN O & M MANUAL

flame scanner cable connection between the terminal block and the head electronics in the field. If continuity is

vanish.

If this fault persists even then,

2/4 flame module may need replacement. Do not insert or pull out any module from the connector when power is ON. This may damage the module. If any module has to be removed for examination or changing the settings, it is safe to switch OFF the power by operating the toggle switch SO1 in the power supply mother board and wait till all the lamps in the power supply module go OFF. Then remove or insert the module and then switch ON the toggle switch SO1 if needed to power up the system.

also alright, then head electronics may need recalibration or replacement. response for mode selection For PB, any other fault in this module like no improper display, etc., the module is to be replaced. In 2/4 flame module, the fault lamp should be OFF for normal operation. If the fault lamp is ON, then fault lamp in any one or more of the flame processor modules may be ON. If that module is attended, this fault may

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BHELSCAN O&M -2