FURNACE SAFEGUARD SUPERVISOTY

SYSTEM
PURUSOTTUM KUMAR

O.P. JINDAL SUPER THERMAL POWER PLANT

(4*250 MW)
TAMNAR , RAIGARH
(C.G)

O.P. JINDAL SUPER THERMAL POWER

PLANT (4*250 MW)
TAMNAR ,
RAIGARH (C.G)

Coal
kaoMines
yala
a

CHP

STEAM
Boiler

WELCOME
HP

IP

LP
WATER

Generator
ELECTRICITY

GT

Cooling Tower

FSSS
The Furnace Safeguard Supervisory
System (FSSS) is designed to ensure
the execution of a safe, orderly
operating sequence in the start up and
shutdown of fuel firing equipment.
The FSSS shall be designed to perform
the following functions Prevent
fuel
firing
unless
a
satisfactory furnace purge has been
completed.
Prevent start-up of the fuel firing
equipment unless certain permissive &
interlocks have been completed.
3/25/16

FSSS
Monitor and control the correct
component sequencing during startup and shut-down of the equipment.
Provide
component
condition
feedback to the operator .
Provide flame supervision when fuel
firing equipment is in service and
effect of fuel trip upon certain
unacceptable firing conditions.
Initiate a MFT of Unit when a certain
abnormal operating conditions exist.
3/25/16

FSSS
The following operational functions are
included in FSSS Furnace purge supervision.

Secondary air damper modulation, On/Off control and

supervision.
Light oil on-off control and supervision.
Heavy oil on-off control and supervision.
Pulveriser and Feeder on-off control and supervision.
Flame scanner intelligence and checking.
Overall Boiler flame failure protection.
Boiler trip protection.
3/25/16

FSSS
FURNACE PURGE-

Before any fuel firing can take place (initially or

after a Boiler trip) a successful furnace purge
cycle must be completed. To start a furnace
purge cycle proceed as follows
Establish AC & DC power to FSSS and the
related equipment.
Establish proper drum water level.
Place at least one ID and one FD fan in service.
Establish airflow between 30% to 40%MCR
through the furnace.
Then check PURGE READY light , If the PURGE
READY light does not come then check all
purge permissive.
3/25/16

PURGE PERMISSIVES
All HONVs and HOTV Closed

All LONVs and LOTV closed

No Boiler Trip (MFT condition
not present)
All Pulverizers Off.
All Feeders Off
A
N All Flame Scanners Sense No
D Flame
Both PA fans Off
All Auxiliary Air Dampers
Modulating
All HAGs Closed
Air Flow > 30 % to 40% of
1080TPH
3/25/16

Press
purg
e PB

DELAY
300
SEC

MFT
RESE
T

PURGE
COMPL
ETE

FSSS
FURNACE PURGEWhen the furnace purge cycle is started by the
operator, by pressing PURGE START push
button, a five minutes purge timer is energized as
indicated by the PURGING" light coming on.
At the end of the five minutes, the boiler trip
circuit is reset, provided no boiler trip command is
present. The "PURGING" light goes out and yellow
PURGE COMPLETE light comes on. Once the
Boiler trip circuit is reset (on purging complete),
the close circuits of H.O. trip valve and L.O. trip
valve are de-energised permitting the operator to
open it as described below 3/25/16

HOTV

3/25/16

HOTV OPEN INTERLOCKS

A
N
D

No MFT
HFO Header temperature satisfactory
HFO supply pressure adequate
All HONVs closed
Atomising steam pressure adequate
HORV open
Unit 24V DC Power supply available

Open HOTV for HFO recirculating and firing

3/25/16

HOTV CLOSE INTERLOCKS

Any HONV not closed

AND

HFO pressure low

OR

Atomizing steam pressure low

OR

OR

HFO Header Temperature Lo-Lo for

2 secspower (24V) > 2 Seconds
Loss of>critical
MFT operated 2/3 logic

3/25/16

10

HORV OPEN INTERLOCKS

H O RECIRCULATION VALVE CONTROL

Before any main fuel can be fired the heavy oil must be
brought to proper temperature.
This is accomplished by recirculating H.O. through the oil
recirculation system by means opening of the H.O.T.V and
H.O. recirculation valves (HORV) .
FSSS permits the opening of HOTV for oil recirculation
purpose following a boiler trip and prior to starting a
furnace purge cycle as follows:
1) Depressing the "H.O. recirculation valve open push button"
will Open the Recirculation valve (long), provided all the
H.O. nozzle valves are fully closed.
2) When the H.O.R.V. is fully open as indicated by the HORV
open light (red) being on, depress the "H.O.T.V. open push
button". This will start the H.O. recirculation .
3/25/16

11

LOTV

3/25/16

12

LOTV OPEN PERMISSIVE

24V DC power available
Atomising air pressure
A adequate
N LDO header pressure
D adequate
All LONVs closed
No auto closing conditions
present
No MFT Open LOTV for oil firing
3/25/16

13

LOTV CLOSE PROTECTION

O
R

3/25/16

MFT 2/3 operated

LDO header pressure V. Low
.
Atomizing Air press V. Low
with time delay 5sec .AND.
any LONV not closed
Loss of 24V DC (unit critical
power)

14

FSS
LIGHT OIL PAIR MODE START
S ( ELEVATION AB )

Light oil can be fired at elevation AB only and in pair basis

Pair firing mode is selected when no feeder is in service. Pairs are
made for the opposite corners. (Pair 1-3 and Pair 2-4)
Oil gun is engaged, corresponding scavenge valve is closed,
atomizing air and LO isolation valves are open.
To place the light oil guns in service proceed as follows:
Select light oil firing.
Establish light oil elevation start permit by the following
conditions being satisfied.
a) No master fuel trip.
b) Light oil trip valve proven fully open.
When pair 1-3 start push button is pressed the following events
take place 70 seconds counting period is started.
HEA ignitor advances and starts sparking.
Atomising air valve opens.
LO Nozzle valve for corner -1 opens
LO catches fire and flame indication comes.
After 15 seconds HEA Ignitor retracts.
When the 30 second counting period expires command will go to

FSSS
H O PAIR MODE START ( ELEVATION
AB ,CD &EF)

Heavy oil can be fired at elevation AB or CD or EF .

Pair firing mode is selected when no feeder is in service. Pairs are
made for the opposite corners. (Pair 1-3 and Pair 2-4)
Oil gun is engaged, corresponding scavenge valve is closed,
atomising steam and HO isolation valves are open.
To place the heavy oil guns in service proceed as follows:
Select Heavy oil firing.
Establish heavy oil elevation start permit by the following
conditions being satisfied.
a) No master fuel trip.
b) Heavy oil trip valve proven fully open.
When pair 1-3 start push button is pressed the following events
take place 70 seconds counting period is started.
HEA ignitor advances and starts sparking.
Atomizing steam valve opens.
HO Nozzle valve for corner -1 opens
HO catches fire and flame indication comes.
After 15 seconds HEA Ignitor retracts.
When the 30 second counting period expires command will go to

FSSS
ELEVATION MODE START UP

Elevation mode of operation is selected when adjacent

feeder is proven.

Oil elevation is placed in service when Pair 1-3 or Pair

2-4 start Push Button is pressed. In elevation mode
also the oil guns are proven on pair basis.

First command goes for placing Pair 1-3 into service

and Pair 1-3 is placed into service in the same way as
in the pair mode.

After the start command has gone to corner 3 a 30 sec.

counting period is started. When 30 sec. counting
period expires then start command goes for corner 2-4
and corner

2-4 are placed into service exactly in the

same manner as in the pair mode.

FSS
PAIR
S -MODE SHUTDOWN

When pair 1-3 stop push button is pressed the following

events take place
A 30 second counting period is started
Oil Gun No-1 HONV closes.
Scavenging and atomizing steam valve opens.
HEA igniter advances and spark remains for 15 seconds.
When atomizing steam valve is proven fully open, a 5
minutes counting period starts.
When 5 minutes counting period expires scavenge valve
and atomizing steam valve closes and further closing
command goes HFO nozzle valves to reinsure that they
are fully closed.
When the 30 second counting period expires stop
command will go to corner 3 and same events will take
place.
Corner 2-4 can
be shut-down exactly in the same
manner.

3/25/16

18

FSS
S-

POST PURGE EXCURSION

PROTECTION

Post purge excursion protection circuit has been designed

in the Furnace Safeguard Supervisory System. It operates
as described below:
When all the following conditions are satisfied, a 5-minute
counting period is started.
Light oil trip valve closed.
Elevation AB all LO nozzle valves closed.
Heavy oil trip valve closed.
All elevation all HO nozzle valves closed.
All Feeders off.
Air flow > 30 % MCR.
All scanners show no flame.
All Hot air gates closed.
All aux. air dampers modulating
All PA fans off.
After 5 minute counting period expires, the Post Purge
Fan Trip memory is set, if very high or very low furnace
pressure exists, the post purge fan trip command is issued
(for tripping of FD&ID fans). When any HO / LO valve is
3/25/16
19
open, this is reset.

BOWL MILL

3/25/16

20

BOWL MILL

3/25/16

21

MILL START PERMISSIVE

Mill Ready Conditions:
Bunker outlet gate open,
Feeder inlet gate open,
MDVs open in all four corners,
Mill outlet temp <95 0 C
CAG open,
Tramp iron hopper valve open
No mill trip
PA permit available
All burner isolation gates open
Feeder in remote
Start permit from PLOS
Start permit from PLOS
Any lube oil pump ON.
Any bearing temp. < 65 OC
LO tank temp <65 OC
LOP discharge press > 0.8ksc
LO filter DP< 1.5ksc
Tank level OK.
LO flow> 120 LPM
PA permit available
PA header pressure no lo-lo
FD Fan ON
3/25/16

Mill start permissive

Mill motor SWGR available

Pulverizer Ignition permit

available
No MFT

N
D

Seal air Header to mill under

bowl DP satisfactory
Mill not ON

Mill ready conditions

22

MILL ELEVATION IGNITION PERMIT

FOR Mill A
O
R

AB elevation 3/4 HONVs / LONVs proven open

Boiler load > 30 % and Feeder - B speed > 50 %.

For Mill B
O
R

AB elevation 3/4 HONVs/LOTVs proven open

Boiler load > 30 % and Feeder A or Feeder C proven with load>50%

For Mill C
CD elevation 3/4 HONVs proven open
O
R

AB oil elev 3/4 HONVs/ LONVs open and Feeder B at 50%loading

Boiler load > 30 % & either feeder B or Feeder D proven with >50% loading

For Mill D
CD elevation 3 / 4 HONVs proven open
O

Boiler load > 30 % and either Feeder- C or Feeder- E proven with >50% loading

For Mill E
EF elevation 3/4 HONVs proven open
O
R

CD oil elev 3/4 HONVs open and Feeder D at 50%loading

Boiler load > 30 % & either feeder -D or Feeder- F proven with >50% loading

For Mill F
O

EF elevation 3/4 HONVs proven open

Boiler load > 30 % & Feeder- E proven with >50% loading

3/25/16

23

FSSS
PULVERIZER START

By establishing Ignition energy available and pulverizer

ready conditions for the respective pulverizer, it may be
placed in service as follows:
Start Pulverizer by pressing its associated "START push
button. First, seal air valve opens, after seal air to bowl DP
adequate pulverizer will start.
When the Pulverizer is proven on as indicated by the (Red)
pulverizer "ON" light, open the hot air gate by pressing its
"OPEN" button and allow the pulverizer to come up to the
temperature.
When the pulverizer comes up to temperature,
(approximately 60 deg. C) Feeder O/L gate open and start
the feeder by pressing its associated "START push button.
Coal flow must be proven either by the coal flow detector or
satisfactory pulverizer current within 15 seconds, after the
feeder is started.
When the feeder is ON for 50 secs. the feeder speed is
released to auto control and the fuel air dampers are
opened to modulate as a function of feeder speed.

PULVERISER TRIP PROTECTION

O
R

Any Pulverizer discharge valve not open.

Loss of unit critical power (24V DC).

Pulverizer ignition permit is not available .

MFT (See boiler trip section for details).

Loss of primary air (PA Header pressure Very low-390mmwc)

Seal air header to pulverizer differential pressure low (125 mm

WC) .AND. Pulverizer on for more than 60 secs.

Any coal burner of that elevation Manual Isolation Valve not

open.

Lube oil system failed.

Pulveriser failed to start for > 10 secs.

Electrical Trip.

All PA Fans tripped

All FD Fans tripped

When one PA fan or one FD fan trips and three or more pulverizers
are in service, each pulverizer with a 2 sec time delay a trip

3/25/16

command will be given starting from the top most elevation, until
the number of pulverizers remaining in service is reduced to

25

FEEDER START PERMISSIVE

Pulveriser Ready is available
Feeder speed demand at minimum (5%)

A
N
D

Feeder in Remote
Pulveriser ignition permit available
No MFT
Pulveriser ON
Feeder SAV open
Feeder O/L gate open

3/25/16

26

FEEDER TRIP CONDITION

Ignition energy removed within 180 seconds
of feeder start
Feeder not in Remote
O
R

Feeder SAV not open

Pulverizer OFF
MFT
No coal on belt

3/25/16

27

BOILER TRIP PROTECTION

Both ID Fans Off 2/3 hardwire contact for each fans from HT SWGR

Both FD Fans Off - 2/3 hardwire contact for each fans from HT SWGR

Both Emergency Push Buttons Pressed from UCP

O
R

3/25/16

Furnace Pressure Lo-Lo (< -175 mmWC, 2 / 3 logic )

Furnace Pressure High-High (> + 150 mmWC, 2 / 3 logic)

Drum Level Lo-Lo (< - 225 mm, delay 5 seconds, 2/3Tx)

Drum Level High-High (> + 225 mm, delay of 10 seconds, 2/3Tx)

Total air flow V. Low ( <30%, 324TPH, FT)

Loss Of Reheater Protection (Acted 10sec arming)

Loss Of unit 220 V DC For > 2 seconds, (LOTV, HOTV, HORV,

Scanner Emergency Damper)

Loss of 24V DC -FSSS internal- MFT pannel hardwired trip)

Loss of 110V AC 2sec (nozzle valve solenoids, arming-all feeders

off)

Unit Flame Failure trip (arming any feeder proven)

Loss Of All Fuel (Arming any HO/LO nozzle valves not closed.)

Less than fire ball and loss of AC.

All Air Heater off

28

FSSS
BOILER
TRIPS
When the Boiler trips the following
events takes place .Boiler trip red
lamp comes on.

MFT A ,B & C trip lamp comes on and reset lamp goes off.
Cause of trip memory can not be reset till the furnace
purge is completed.
F D Fans Control is transferred to manual.
I D fans vane position is transferred to manual.
Pulverizers and coal feeders are tripped.
P A Fans are tripped.
HFO & LDO trip valve closes.
All HFO Nozzle valves closes.
Auxiliary air damper opens and control is transferred to
manual.
S/H and R/H spray block valves closes and can not be
opened unless furnace purge is completed.
Turbine Trips

FSS
BOILER TRIP PROTECTION
S - LOSS OF ALL FUEL TRIP
THE LOSS OF ALL FUEL TRIP CIRCUIT BECOMES ARMED ONCE
ANY ONE NOZZLE VALVES LIFTS FROM CLOSED POSITION IN
ANY ELEVATION.
ONCE THE TRIP CIRCUIT IS ARMED, LOSS OF FUEL TRIP WILL
OCCUR,IFALL FEEDERS ARE OFF.

AND
LOTV/HOTV IS NOT OPEN. OR ALL ELEVATION LONV /HONV
CLOSED.

FSSS
BOILER TRIP PROTECTION
12- UNIT FLAME FAILURE TRIP
RUNNING COAL ELEVATION ADJACENT FIRE
BALL SCANNER ARE NOT SHOWING
2/4FLAME & IT IS NOT SUPPORTED BY
3/4 OIL GUNS THEN THESE ELEVATION NO
FLAME OR FLAME FAILURE OCCURED.
IF THESE CONDITION OCCURED IN ALL
ELEVATION THEN UNIT FLAME FAILURE.

FSSS
BOILER TRIP CONDITIONS
ANY FEEDER PROVEN (FEEDER ON >50 SEC.)

ELEVATION EF NO FLAME VOTE

ELEVATION DE NO FLAME VOTE
FLAME FAILURE TRIP
ELEVATION CD NO FLAME VOTE
ELEVATION BC NO FLAME VOTE
ELEVATION AB NO FLAME VOTE

FSSSBOILER TRIP CONDITIONS

REHEATER PROTECTION TRIP
REHEATER PROTECTAION TRIP LOGIC BECOME ARMED WHEN ANY
COAL FEEDER PROVEN
ONCE THE TRIP CIRCUIT IS ARMED, REHEATER PROTECTAION TRIP
WILL OCCUR, IF

GENERATOR CB OPEN & MS PRESS.>20 KG/CM2

BOILER WILL TRIP AFTER 10 SEC. DELAY

ANY HPBP OR LPBP < 2 %

GENERATOR CB CLOSE
ANY HPCV & HPBP < 2 %
ANY IPCV & LPBP < 2 %

BOILER WILL TRIP AFTER 10 SEC. DELAY

FSSS
SCANNER AIR FAN
CONTROL
Scanner fan A
- or B can be started manually by

depressing the respective START PB.

Scanner fan A or B will start automatically
whenever the scanner duct to furnace differential
pressure goes low (250 mmwc). AND. No MFT .OR.
When there is loss of unit critical power (24 V DC).
if one scanner fan fails to start within 5 secs. after
receiving the start command, the other scanner
fan will start automatically.
Scanner fans A or B can be stopped by depressing
the respective STOP PB provided there is No
start command .AND. Scanner duct to furnace
differential pressure is more than the preset
value.
When both the FD fans are off .OR. Loss of unit

FSSS
-

3/25/16

35

FSSS
SEAL AIR FAN CONTROL

:-

There are two seal air fans that serve air for mill and
feeder sealing, one working and one standby.
Any seal air fan can be started manually by depressing its
START PB. This action gives start command to the motor.
The seal air fan which is not in service is started on Auto
command if, Any PA fan is on .AND. Seal air header to cold
PA header DP is low for > 10 secs
The seal air fan A will start automatically 5 sec. after the
seal air fan B trips or fails to start on receiving start
command (SA fan B starts automatically if SA fan A
fails to start).
Any seal air fan can be stopped by depressing its STOP
PB, provided the following conditions are satisfied.
Seal Air Header / Cold Air duct DP not low
.AND.
Both Seal Air fans on
Both Seal Air Fans are tripped once Both PA Fans are off >
15 Secs .

FSSS
-

3/25/16

37

FSSS
-

SADC

3/25/16

38

FSSS
-

FUNCTION

The function of Secondary Air Damper Control System (SADC) is to

proportion the total secondary air around the firing elevation as per the
criteria.
The amount of fuel fired and the no of firing elevations decide the damper
position.
Each wind box assembly is divided into 13 compartments.
There are 6 elevations which houses coal nozzles for firing the main fuel.
There are 3 elevations which houses oil burner assembly
There are two nos. of over fire air compartment at the top of the windbox.
They are designated as OFA-L (Over fire air - Lower) and OFA-U ( Over fire air Upper) respectively.
If secondary air is admitted to a fuel compartment in service, it is referred as
fuel air(FA).
Secondary air is admitted to the furnace through air compartments and fuel
compartments not in service, is termed as auxiliary air(AA).
The auxiliary air damper control is separate from the fuel air damper control.

Aux Air damper position changes to maintain windbox DP

fuel air damper positions versus the fuel feed rate is to be decided for the
type of coal used.
3/25/16

39

FSSSAUXULIARY AIR CONTROL

All elevations of the aux. air dampers will be automatically switched to modulation
control and then commanded to open 100%, if any one of the following conditions
exist.

Also the auxiliary air control loop is tripped to manual if any of the following
conditions exist.

All FD fans are off

All ID fans are off
Master fuel trip exists
Loss of Unit +24 V DC power

DP transmitter deviation high.

Windbox to Furnace DP very high (> 240mm WCL).

When the auxiliary air control is placed in the Auto mode of operation , the
auxiliary air dampers modulate to control wind box to furnace differential pressure
at a predetermined set point.
During the furnace purge cycle, all auxiliary air dampers modulate to maintain
windbox to furnace differential pressure at a predetermined set point.
When the unit load exceeds 30% of MCR, the following events occurs :

The wind box to furnace differential set point is gradually increased as the unit
load is increased. Conversely, the differential pressure set point is gradually
decreased as unit load is decreased.
The rate of increase (or decrease) is controlled by the auxiliary damper
controller.

The wind-box to furnace differential pressure set point reverts to its original
value during putting in auto.

When the Post Trip Purge Time Expired command is established and all FD / ID
fans are not off and a Master fuel trip command doesnt exist, then a 35 40
3/25/16
seconds counting period is started. After it expires, the Open All Auxiliary Air

AUXULIARY AIR DAMPER CONTROL

Above 30% MCR boiler
load, the auxiliary air
elevation
associated
with the main fuel
elevation
in
service
modulate to maintain
the varying DP. Those
not
associated
with
any
elevation
in
service are closed from
top to bottom. The
closing signal comes
from FSSS.
When the unit load is
increased above 30%
MCR,
the
Aux.
air
dampers of elev. AB,
BC, CD, DE, EF & FF are
closed
in
a
timed
sequence
(10
sec.
interval) provided the
associated
coal
elevations
are not in
3/25/16
service
and
the

41

FUEL AIR DAMPERS CONTROL

All elevations of fuel air dampers are
commanded to open 100% when any one
of the following conditions exist.
All FD fans are of
All ID fans are of
Master fuel trip exists .
Loss of Unit +24V DC power

When a coal elevation is in service, the

associated fuel air dampers modulate as a
function of feeder speed as indicated by
the associated coal elevation
MODULATING light coming on.
When the coal elevation is shut down, the
associated fuel air dampers are closed, as
indicated by a CLOSED light.
3/25/16

42

OFA DAMPER INTERLOCKS

The two elevations of the over fire air
dampers will be automatically switched to
Manual control and then commanded to
open 100%, if any one of the following
conditions exist:

3/25/16

Master fuel trip occurs.

Loss of unit critical power .(+24 VDC)
Both FD fans are OFF.
Both ID fans are OFF.
WB To Furnace DP exceeds 240mm WCL.

43

MODULATION OF OFA
DAMPERS

3/25/16

44

THANK YOU
3/25/16

45