INDEX

SR.NO.
1

PARTICULARS INTRODUCTION 2

PAGE NO.

SIGNIFICANCE 3

OPERATION 4

EQUIPMENT 5

FURNACE PURGE 7

LIGHTING UP WARM UP ELEVATION 10

LIGHTING UP HEAVY OIL ELEVATION 16

MILL 18

FAN CONTROL 25

10

CONTROLS OF WIND BOX DAMPER 26

11

FSSS PROTECTION TO BOILER 27

12

FSSS ANNUNCIATIONS 28

13

CARE OF FSSS 29

INTRODUCTION

Furnace safeguard supervisory system popularly called FSSS continuously monitors the operations related to fuel admission and some other vital parameters to ensure safety of the Boiler. Generally furnace oil or any kind of fuel is susceptible to explosion hazards. Majority of explosion occurs during start up, shut down and low load operations. There are many steps that must be followed by the operator to admit a fuel in to the furnace safely and properly. In high capacity boilers, where fuel input rate is very high major furnace explosions can result from the ignition of unburnt fuel accumulated in the first one or two seconds. Human reaction time to such situations is inadequate. So there a proper burner management system called as FSSS is installed in the Boilers. Every operation related to fuel admission is accomplished through FSSS.

SIGNIFICANS

The furnace explosion occurs due to:

a)

Improper purging of the furnace and air.

b) Inadequate ignition procedures. c) Maintaining fuel supply for too long a period without establishing combustion. d) Re-lighting burners too soon after previous flame out. e) Introduction of main fuel without ensuring adequate ignition energy. So furnace burning any and all kinds of fuels is susceptible to explosion hazards. FSSS helps in achieving basic objectives repeatedly without error to safe-guard the furnace against hazardous effect by means of a) Ensuring certain Safe condition established and proved in the furnace before light up can proceed. b) In the case of unstable furnace flame condition, to help the operator to introduce additional ignition energy. c) In the event of flame failure fuel supply is immediately cut off and furnace, air and gas paths purged before any attempt is made to relight the burners.

OPERATION
Furnace safeguard supervisory system comprises of controls, indications, logic to carry out following: 1) To start and complete furnace purge when all technological conditions are fulfilled.
2)

To start and monitor igniters.

3) To start warm up or heavy oil guns when permissive condition exits. The guns are allowed to burn so long as proper combustion conditions are ensured. 4) To start mills and coal feeders when safe conditions exist. 5) To trip out mills and coal feeders when satisfactory conditions cease. 6) To trip out all boiler fines when boiler safety is threatened 7) To monitor furnace flame. 8) To start and stop igniter and scanner fans. 9) To indicate auxiliary and fuel air damper close and modulation indications.
10)To

release damper interlocks for secondary air control.

11) To provide boiler trip signal to other equipment such as PA fans, turbine generator etc.

EQUIPMENT
So, FSSS system is designed to offer a maximum safety, minimum trips, minimum power consumption and maximum life for the component used. The logic is functionally divided into unit logic, elevation logic and corner logic. Unit Logic: it supervises the overall furnace condition by monitoring all critical parameters of fuel firing system and also supervises furnace purge. Elevation Logic: start up and stopping actions for the elevation are carried out through this logic. Corner Logic: it controls and supervises the corner was that is oil valves, atomizing valves. FSSS Equipment can be group under three heads: Operating and indicating console insert on the operators desk: this consist of all the switches for initiating controls and also indications of status of all fuel firing equipment and their auxiliaries. The operator is

mainly concerned with this desk only provided other two are functioning properly.

Relay logic cabinets: This cabinet consists of relays, timers, circuit breakers for AC, DC, and control supplies flame scanner. The control the process logic. Field Equipment: Field equipment are those which help in actual operation of fuel firing equipment and those which provide the status to the operating consol and relate logic cabinet. Field equipments are trip was valves on the main oil headers, hydro motor valves on oil lines of individual corner, oil guns and atomizing medium of oil gun assembly, igniters, flame scanners, pressure and temperature switches, scanner fans, igniter fans, mill discharge valves, hot air gate, cold air gate, tram iron gate, seal air gate etc. the connection form field equipment to relay logic cabinet is through cables. Connection from operating console to relay logic cabinet is by cables for easy maintenance.

FURNACE PURGE
Furnace purge is required after a boiler trip out, before relighting the boiler to expel all unburnt full particles, vapor etc, form the boiler so that when spark is introduced during light up, possibility of explosion are avoided. FSSS ensure a proper furnace purge in following manner:- Purge Ready signal when appear only when following conditions are fulfilled. 110V AC and 220V DC supply to FSSS panel is switch on. Boiler Drum water level normal. At least one ID and one FD fan running. Establish 30% full load air flow as seen in total air flow recorder.

Igniter trip valve closed.

Warm up trip valve closed. Heavy oil trip valve closed.

All igniter valves closed.

All warm up and oil gun valve closed.

All auxiliary air damper modulating to maintain air flow can adequate wind box to furnace differential processing?

All coal mills off. All raw coal feeders off.

All flame scanners show no flame.

All mill hot air gates closed and cold air damper are less than 5 degree open.

No boiler trip command. When above conditions are met, signal purge ready will disappear, even during purging process. When signal purge ready appears, press button push to purge after the expiry of purging time signal purge complete appears.

454

LIGHTING UP WARM UP ELEVATION

Now we are ready for Boiler light up.
a)

Lighting up warm up elevation AB Elevation AB has capability to be used for either burning light oil or

heavy oil. So select light oil on the consol for AB elevation ensure warm up oil tips are provided is guns of that particular elevation.
b)

I] Igniter trip valve:

Press igniter trip valve open push button igniter trip valve oil open provided the following condition are fulfilled. Igniter oil supply pressure adequate (more than 12.1 kg/cm2) All igniter valves closed. No boiler trip command. In addition, instrument air supply must be available to actuate trip valve. If igniter fan is not started, it will start when first igniter start Command is given. II] Opening light oil trip valve: Light oil trip valve will open if following condition is met:

No boiler trip.

Elevation AB LO valves on guns is closed. Light oil pressure adequate i.e. they should not less than 1.4 kg/cm2

for more than 25 sec. and light oil trip valve open push button pressed. The following figure shows logic diagram for warm up oil trip valve control. Before Boiler light up with Light Diesel oil, LOTV must be open by giving open command from push button switch on the desk.

Output form OPEN push button switch goes to an AND gate. Other input to this gate are_ 1. No Boiler Trip 2. All Corner Valves closed 3. LDO Pressure Adequate 4. LOTV Close command not persisting When all these inputs are TRUE, OPEN command causes AND gate to give a TRUE output causing LOTV to open.

LOTV closes when

1. 2. 3.

Close command through push button switch is initiated OR Boiler trips OR After a delay of 3 second when any warm up oil elevations Corner valve is NOT CLOSE AND
i) ii)

If LDO Pressure drops to LOW valve OR If P between atomizing air and LDO is low.

Dia fig3 455

c)

Starting Igniter: When igniter is started for 1st 10 sec period, oil and atomizing air are

admitted though the valve and simultaneously a spark is applied. The spark lights up the oil spray and flame is sensed by flame sensor in the igniter. This happen within 10 secs, the valve is held open allowing igniter to continue. There are no separate igniter start push buttons, pressuring any one pair of oil gun start or stop push button will give starting impulse to all four igniter of that elevation. To start the oil guns press either 1and 3 or 2 and 4 start button. This gives commands for igniter start provided the following condition is met: DC power available. No boiler trip command.

Burner tilt horizontal and air flow less than 40%.

Igniter trip valve open. L.O. trip valve are open.

Igniter start causes following gives a start command to spark plug. This command holds for 10 secs by which time if flame is in the igniters. Now in this way at least three igniters on selected elevations are proved command is given for selected LO guns to advance and light up provided:
o

Atomizing air valve open

o Warm up oil valve open.

o

Corresponding igniter proved.

Under this condition, first one gun will advance, atomizing air will open the next gun of will undergo similar operation with time log off 25 secs in this at least three guns have to be proved, otherwise oil guns will trip out. When guns trips , the gun will not retract , it must be retracted locally immediately to avoid any fire accident.

Warm up guns will trip under following conditions: Pressing stop push button.

Moving local switch from Remote to any other position.

 Gun advanced or engaged limit switches are released.

Corresponding igniters trip out.

Air or oil is elevating valve are closed.

Oil valve is not proven to be open within 90seconds.

Any boiler trip command.

At any time when warm up guns are in service, it more than one igniter is off all warm up guns oil trip.

LIGHTING UP HEAVY OIL ELEVATION

I] Lighting up Heavy Oil Elevation. Healy oil can be fired on any three elevation AB,CD and EF. Heavy oil guns are supposed to be self sustaining. Once three oil guns are tilt, their flow (gun loading in that particular elevation) is more than 30% or Boiler load more than 30% and flame scanners are sensing flame under these condition light oil can be withdrawn without affecting oil guns. II] Now the heavy oil valves open under following condition are met.

Header oil pressure adequate.

All heavy oil hydra motor valve of AB, CD, EF oil guns are proven closed. No boiler trip command.

Heavy oil pressure not low less than 1.4 kg/cm2 for more than 2 secs. When valve open signals open appears on the panel. Starting igniter command oil materialize only when heavy oil is

ready for light up with oil temperature more than 1050C . Now taking heavy oil guns service in elevation AB.

Gun will advance provided: Atomizing steam isolating valve open. Heavy oil manual isolating valve open.

Heavy oil igniter on.

Under this condition oil gun advance.

MILL
FSSS controls the salve starting, running and stopping of mills.
a)

Pulverizer Ready for start

This is common to all six mills signal pulverizer ready will appear when all the following conditions are fulfilled.

Mills outlet temperature is less than 900C.

 Seal air valve open. Cold air gate open. Feeder inlet gate open,

Pulverizer discharge valve open.

Tramp iron hopper gate open.

No Pulveriser trip command. Burner tilt horizontal and air flow less than 40% for subsequent mills, the first R.C. feeder ON. Energizes relay by passing burner tilt and air flow conditions.

Dia fig 4. 456

b)

Ignition permissive :

It is presumed that P.A. fan is running, seal air fan is running, P.A. header pressure is normal before we can actually start the mill, another conditions that of providing sufficient ignition energy near the burner

nozzle of the mill has to be ensured so that, once coal flow is established through mill, the pulverized coal will light up inside the boiler without any loss of time. At least three oil guns (Heavy oil or warm up) are in service for the first mill to be started A or B, C or D, E or F. For second mill to be start ignition energy is given by either: Three oil Guns being in service adjacent to mill or Boiler load is more than 30%.

Adjacent mill running with RC feeder speed in excess of 5rpm or Pulverizer A or C in service at igniter than 50% loading.

This ignition energy must be continuously available for three minutes after starting RC feeder. Even though the logic permits removal of ignition energy after three minutes operationally it will be required for even longer period till boiler flame conditions are stable.

The following figure shows Logic Diagram for Ignition Permissive for Pulverizer A and B. Similar requirements are applicable for other Pulverizers:

1)

Pulverizer B is running with 50% loading AND Boiler Load is More than 30% OR
a)

Elevation AB in service with 3 out of 4 Guns established.

2) Puloverizer B Ignition Permissive is available if

a)

Pulverizer A or C running at 50% loading AND Boiler load is more than 30% OR

b) Oil Elevation AB in service with 3 out of 4 Guns established.

Dia fig. 457

Actual starting of the mill If conditions are met and if local key release push button is released mill can be started by pressing the start push button on console.

 As soon as mill starts, cold air damper opens full.

Hot air gate can now be opened provided temperature after mill still remains less than 900C. If the temperature exceeds 900C, the white signal Pulverizier ready will disappear but the mill will continue to run. Pulversier ready can disappear for other reason also.

However if discharge damper closes mill will trip immediately.

After opening the hot air gate, cold air and hot air damper can be regulated to achieve an after mill temperature of 600C to750C and P.A. fan flow about 52 T/hrs. During manipulation of air, take care load P.A. fan so, that P.A. header pressure does not fall below 650mm.

If the ignition energy continuous to be present after starting mill, feeder can be started and mill loaded.

As soon as feeder is started, signal given to panel to modulate fuel air accelerator to speed of feeder. When feeder stops, fuel air damper is shut. This is to facilitate quick light up of fuel when a mill is started.

After 50 seconds of feeder starting relay energizes to permit feeder to be controlled by boiler pressure auto.

PULVERIZER START

When ignition energy available and Pulverizer ready condition are establish for the respective Pulverizer. The Pulverizer may be place in service as follows: a) Start the Pulverizer by pressing start push button
b)

When Pulverizer is proven on as indicated by its on indication or by amp on UCR open, hot air gate and allow pulverize to come adequate temp (750C) and PA flow of about 52 T/hr with the help of cold air damper.

c)

When Pulverizer is up to temp 1400C start feeder and set at minimum and associated elevation of fuel air damper proven close.

Coal flow must be proven either by coal flow detector or satisfactory Pulverzier amp within 5 secs after feeder started. When minimum of the two feeders are establish at greater than 50% loading, associated elevation of oil guns may be shutdown provided feeder has been on for minimum 3 of 3 minute.

FAN CONTROL
Igniter and scanner fans:

Igniter fan:Igniter can be started from control desk otherwise it get set started automatically when any igniter or oil elevation start is initiate at least one ID and more than one FD fan must be service for the igniter fan to start on stopping igniter fan from control desk will remove the associated igniter fan service provided all of igniter valve are closed. Scanner Fan Control:It can be started from control desk otherwise it get started automatically when the scanner air duct to differential pressure falls below 4.5w.g. low differential pressure more than 10 secs will alarm, the scanner emergence damper open on interlock when both ID/FD fan are off, this allows the fan to draw ambient air for the cooling scanner when unit is bottled up on stopping fan from control desk will remove the scanner fan from service provided the scanner duct to furnace desk. Pressure is above 4.5w.g.

CONTROLS THE WIND BOX DAMPERS

1] Auxiliary Air Dampers:

 During furnace purge and when load is less than 30%. FSSS modulates are auxiliary air dampers to maintain a low wind box pressure (30mm). When load increases beyond 30% the modulation is for a higher wind box pressure (60mm), which is achieve by closing dampers near elevation not in service. When warm up oil is in service, the auxiliary air damper of AB elevation opens to a predetermined position. When heavy oil is in service, the auxiliary air is allowed to be controlled by opening depending on oil pressure. When one FD fan trips, then all auxiliary and fuel air damper open wide.

2] Fuel air dampers:

All the air dampers are shut on elevations where there are no feeders in service. After starting of feeder, the fuel air damper of that elevation is allowed to be controlled with feeder speed.

FSSS PROTECTS THE BOILER

By tripping out all fuel i/p under the following condition: Loss of D.C. to FSSS Furnace pressure inadequate. Less than fire ball load and loss of A.C. on any elevation in service. Drum level high or low. Flame failure trip. Both PA fan off. Low air flow. In this way FSSS protect the boiler hence it is said to be furnace safeguard supervisory system.

FSSS ANNUNCIATIONS
F.S.S.S. Provide the following Annunciations/ contacts:

Both ID & FD fans (one pair) off.

Air flow is less than 30% when boiler load is less than 30%. Scanner fault alarm. Stand by scanner fan started. Furnace pressure high/low.

Both P.A. fans off when any pulverizer is ON.

Drum level high/low. Turbine trip. Heavy oil Header Pressure low. Loss of A.C. power.

CARE OF FSSS
To get maximum utilization out of FSSS the following are recommended: These notes serve as a guide for boiler operation engineers. Relay numbers have been given for their understanding only. No repair o tinkering on FSSS panel is allowed by operation engineers. Relay logic panel must be handled by only the control maintenance engineers deputed for the purpose. All check and repair must be based on engineering drawing. FSSS panel and console must be kept clean. Periodic vacuum cleaning or air blowing is advised. FSSS panel must be kept closed and locked if necessary. Earth fault relay occur in the panel wiring and relays. Frequent source or fault lie in the field equipment and connecting with FSSS

must be periodically inspected; leakages eliminated, kept clean and smooth working should be constantly at relay panel to make good failures of field equipment. Gun advance retract mechanisms, limit switches, hydra motor valve, trip valves pressure, temperature switches etc. require periodic cleaning, lubrication and other appropriate maintenance.