1 RC Feeder Interlock & Protection

RC FEEDER INTERLOCK & PROTECTION
PROTECTION& INTERLOCK
CLASSIFICATION OF BOILER PROTECTIONS & INTERLOCKS FURNANCE SAFEGAURD SUPERVISORY SYSTEM(FSSS) This system takes care of interlocks required for starting, supervising the operating & safe shutdown of the equipments connected with fuel firing system like 1) Purge Interlock 2) LOTV control & supervision 3) HOTV control & supervision 4) Pulveriser interlocks 5) SADC- on/off & supervision 6) Flame Intelligence & checking 7) Boiler flame failure protection 8) Boiler Trip protection BOILER AUXILIARIES INTERLOCK & PROTECTION This system takes care of sequence of starting protection & interlock of boiler auxiliaries like 1) ID fans 2) FD fans 3) PA fans 4) APH 5) MILL 6) RC FEEDER 7) REHEATER Protection
Furnace Safeguard Supervisory System(FSSS)

Introduction to FSSS Furnace safeguard Supervisory System It is designed to ensure the execution of safe, orderly operating sequence in
start up and shutdown of fuel firing equipments and to prevent error of

omission and commissioning in following such a safe operating procedure. FSSS system supervises, controls and monitors the preparation, distribution and admission of fuel & air into the furnace and execution and enforcement of pre-established safe firing procedure. The FSSS provides permissive interlocks only to ensure safe start up sequence of equipment.
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FSSS is designed to perform the following functions:

Prevent any fuel firing unless a satisfactory furnace purge sequence has
first been completed. Prevent start-up of individual fuel firing equipment unless certain permissive
interlocks have first been satisfied.

Monitor & control the proper sequence (Manual or Automatic) during startup and shutdown of fuel firing equipment. Make continued operation of fuel firing equipment subject to certain safety interlocks remaining satisfied. Provide status feedback to the operator and in some cases, to the unit control system. Provide flame supervision when fuel firing equipment is in service and affect a fuel trip upon certain adverse operating conditions. Initiate a fuel trip when certain abnormal operating conditions exist.
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FSSSs Operational Function:

1) FURNACE PURGE SUPERVISION.
2) LIGHT OIL ON/OFF CONTROL & SUPERVISION. 3) HEAVY OIL ON/OFF CONTROL & SUPERVISION.
4) PULVERISER CONTROL & SUPERVISION. a. Pulveriser discharge valve control. b. Pulveriser ignition permissive. c. Pulveriser ready permissive. d. Pulveriser on/off control. e. Hot air gate open/close control f. Feeder start/stop control.
5) SADC - ON/OFF CONTROL & SUPERVISION. 6) FLAME SCANNER INTELLIGENCE & CHECKING. a. Scanner air fan control. b. Flame scan output indication. c. Flame failure trip. 7) BOILER TRIP PROTECTION
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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 furnace purge
cycle
Establish AC/DC supply to FSSS equipments. Bring normal water level in drum. Take at least one ID&FD fans in service. Establish airflow between 30% to 40% of MCR
A N D PURGE READY
PURGING
START PURGE
Press START PURGE button

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5 minute count down timer ON RC FEEDER INTERLOCK & PROTECTION

Furnace Purge
If PURGE READY signal is not available, then check the following conditions are satisfied
Light oil trip valve is proven closed.

Light oil nozzle valves are proven closed. Heavy oil trip valve is proven closed. Heavy oil nozzle valves are fully closed. All PA fans are off. All feeders are off. All hot air gates are fully closed. All the flame scanners show NO FLAME No boiler trip command is present. Airflow between 30% & 40% MCR. All auxiliary dampers are modulating.
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LIGHT OIL TRIP VALVE CONTROL(LOTV) Conditions to be fulfilled to open LOTV after successful purging A Light oil supply pressure is adequate LOTV OPEN N All LO nozzle valve proven closed in AB elev Permissive ok D Conditions leading to close LOTV automatically MFT Any Light oil nozzle valve not closed Light oil header pressure very low
and or
Tripping command to close LOTV
Any light oil nozzle valve not closed Atomizing air pressure very low No light oil Start/Stop in Elevation AB
AIR FM LDO LOFCV
and
To AB elevation burners
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LOTV

HEAVY OIL TRIP VALVE CONTROL(HOTV)
HOTV opening conditions HORTV is fully open HOTV close command is not present All heavy oil nozzle valves are closed No MFT condition is present HO supply pressure is adequate HO supply temperature is adequate HOTV close command is not present
FM
HFO
Return line to tanks
and
or and and
HOTV OPEN permissive satisfied
HOFCV
HOTV
To AB,CD,EF elevation burners
HORTV
Steam

HEAVY OIL TRIP VALVE CONTROL
HOTV closing conditions
Master fuel trip
and
HO Recirculation valve is not closed

If any of the conditions exist for more than 5 sec Atomizing steam pressure very low No HO start or stop in any elevation Any HO nozzle valve not closed
or and or
CLOSE command to HOTV
HO header pressure very low
and
Any HO nozzle valve not closed
HO header temperature very low Any HO nozzle valve not closed

and
10 RC FEEDER INTERLOCK & PROTECTION
*Also HO commanded to close under loss of 220VDC

PULVERISER CONTROL
PULVERSISER DISCHARGE VALVE CONTROL:
The pulveriser discharge valve can be opened manually by depressing the push-button on the console insert.
The valve can be manually closed by the push-button on the console insert only when the pulveriser is off. The corresponding indications are available on the console insert as Red and Green lamps for open and close positions respectively

PULVERISER CONTROL
PULVERISER IGNITION PERMIT:
Prior to starting any feeder, the feeder ignition energy must be adequate to support coal firing. This is accomplished all 6 elevations as follows: PULVERISER "A A minimum of 3 of the 4-elevation AB oil nozzle valves proven open Permit signal to or start PULVERISER A Boiler loading is greater than 30% and Feeder B is in service at greater than 50% loading PULVERISER "B A minimum of 3 of the 4-elevation ABoil nozzle valves proven open Boiler loading is greater than 30% Feeder A is in service at greater than 50% loading. Feeder C is in service at greater than 50% loading.
or
and
or
Permit signal to start PULVERISER B
PULVERISER "C" A minimum of 3 of the 4-elevation CDoil nozzle valves proven open Boiler loading is greater than 30% Feeder B is in service at greater than 50% loading and or Feeder D is in service at greater than 50% loading A minimum of 3 of the 4-elevation ABoil nozzle valves proven open Feeder B is in service at greater than 50% loading.
or
Permit signal to start PULVERISER C
and
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PULVERISER CONTROL
PULVERISER IGNITION PERMIT:
PULVERISER "D" A minimum of 3 of the 4-elevation CD oil nozzle valves proven open. Boiler loading is greater than 30% Feeder C is in service at greater than 50% loading. Feeder E is in service at greater than 50% loading.
and or or
Permit signal to start PULVERISER D
PULVERISER "E A minimum of 3 of the 4-elevation EFoil nozzle valves proven open Boiler loading is greater than 30% Feeder D is in service at greater than 50% loading. or Feeder F is in service at greater than 50% loading. A minimum of 3 of the 4-elevation CD oil nozzle valves proven open Feeder D is in service at greater than 50% loading.
and
or
Permit signal to start PULVERISER E
and
PULVERISER "F A minimum of 3 of the 4-elevation EFoil nozzle valves proven open. Boiler loading is greater than 30% Feeder C is in service at greater than 50% loading
or
and
Permit signal to start PULVERISER F

PULVERISER CONTROL
HOT AIR GATE(HAG) CONTROL: CONDITIONS FOR HAG OPEN
PULVERISER ON
and
PULVERISER AUTO START
or and
OPEN COMMAND TO HOT AIR GATE
MANUAL MODE OPEN HAG FROM PUSH BOTTON
CONDITIONS FOR HAG
CLOSE
or
CLOSE COMMAND TO HOT AIR GATE
CLOSE HAG COMMAND EXIT>30 SECS PULVERISER OFF LOSS OF 24V DC IN ELEVATION

MASTER FUEL TRIP
If some abnormal condition occurs(like less than 30% air ), Master Fuel Trip Relay acts and ensures the closure of Heavy Oil Trip valve (HOTV) and all
light Oil Nozzle Valves (LONV), thus cutting off total oil supply.
Thus MFT ensures a safe shut down of the boiler in case of any abnormal conditions in boiler/ furnace. It also ensures the stopping of all pulverizer systems and Primary Air (PA) fans, cutting off total coal supply to boiler. The various abnormal operating conditions under which Master Fuel Trip occurs are as follows:-

MASTER FUEL TRIP CONDITIONS
1. Drum level very low > 5 seconds. 2. Drum level very high > 10 seconds.
3. Both FD Fans off.

4. Both ID Fans off. 5. Air flow is less than 30% (318.03Tons/Hr ) 6. Furnace pressure very low.
7. Furnace pressure very high.

8. Loss of all fuel trip. 9. Unit flame failure trip. 10. Loss of 220V DC for more than 2 seconds
11. Less than fire ball and loss of 110V AC at any elevation in service.
12. Loss of Reheater protection. 13. Both emergency trip Push Buttons pressed (Operator initiated boiler trip). 14. Spare trip.

MASTER FUEL TRIP CONDITIONS When MFT acted, simultaneous impulses shall be given for :1) Closing all the nozzle valves (LONV/HONV) and trip valves (LOTV/HOTV). 2) All fuel inputs are stopped by tripping all the mills. 3) Closing all hot air gates(HAG).
4) Tripping all the feeders.

5) All fuel air dampers are opened 100% and transferred to manual. 6) All auxiliary air dampers are opened 100% and transferred to manual.

FLAME SCANNER INTELLIGENCE AND CHECKING
SCANNER AIR FLOW CONTROL FLAME SCANNER OUTPUT INDICATION FLAME FAILURE PROTECTION
During light up and until any main fuel (coal) is in service at a fire condition, the flame scanners do not take part in the overall flame failure protection system. A fire ball condition is established for coal firing when either or both the adjacent feeders are proven .AND. 2 out of 4 fireball scanners show flame.

SCANNER AIR FAN CONTROL
Two scanner air fans (1 AC main + 1 DC stand-by) are provided for the unit. 1)AC scanner fan will automatically start if following condition are fulfilled:
After completion of PURGE ON MFT AND LOGIC AC Scanner Fan will automatically start
2)DC scanner fan will automatically start:

AC scanner fan doest start >5secs AC scanner fan trips Low DP across Furnace to Scanner Duct> 10 secs OR Start cmd to DC Scanner Fan
LOGIC
3)In the event of 24VDC failure or all FD fans off, scanners atmosphere emergency suction damper will open(at normal condition suction from FD discharge)
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FLAME SCANNER OUTPUT INDICATION
For AB elevation Feeder B proven Elv. AB 2/4 FB scanner show flame Feeder A proven
LOGIC OR
AND ELE AB FLAME LOGIC
>2secs
Arming signal to FLAME FAILURE TRIP PROTECTION
*Same similar flame indication logic for BC,CD,DE,EF

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FLAME FAILURE PROTECTION:
An elevation voting for "No Flame" condition is as described below for the respective coal and oil elevations.
ELEVATION A
Feeder A is not proven Elevation AB- 3/4 Fireball scanners shows no flame Elevation AB HO/LO- 2/4 nozzle valves not open Elevation AB started and loss of 110V AC power ELEVATION B Feeder B is not proven. Elevation AB- 3/4 Fireball scanners shows no flame Elevation AB HO/LO- 2/4 nozzle valves not open
and or
ELEVATION A VOTED NO FLAME
and or and
Elevation AB started and loss of 110V AC power Elevation BC 3/4 fire ball scanners show no Flame
ELEVATION C Feeder C is not proven. Elevation CD- 3/4 Fireball scanners shows no flame Elevation CD HO- 2/4 nozzle valves not open. Elevation CD started and loss of 110V AC power. Elevation BC- 3/4 fire ball scanners show no Flame
ELEVATION B VOTED NO FLAME
and and
or
ELEVATION C VOTED NO FLAME
RC FEEDER INTERLOCK & PROTECTION FSSS
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FLAME FAILURE PROTECTION(cont): ELEVATION D Feeder D is not proven Elevation CD 3 out of 4 Fireball scanners shows no flame Elevation CD HO 2 out of 4 nozzle valves not open Elevation CD started and loss of 110V AC power Elevation DE 3 out of 4 fire ball scanners show no Flame ELEVATION E Feeder E is not proven Elevation EF 3 out of 4 Fireball scanners shows no flame Elevation EF HO 2 out of 4 nozzle valves not open Elevation EF started and loss of 110V AC power Elevation DE 3 out of 4 fire ball scanners show no Flame ELEVATION F Feeder F is not proven. Elevation EF 3 out of 4 Fireball scanners shows no flame Elevation EF HO 2 out of 4 nozzle valves not open Elevation EF started and loss of 110V AC power
and or and
ELEVATION D VOTED NO FLAME
and and
or
ELEVATION E VOTED NO FLAME
and
or
ELEVATION F VOTED NO FLAME
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FLAME FAILURE PROTECTION(cont):
Any of feeder proven Elv. F voted no flame Elv. E voted no flame Elv. D voted no flame Elv. C voted no flame Elv. B voted no flame Elv. A voted no flame All elevation voting for No Flame" as described above will cause a unit trip on Flame Failure trip, provided the flame failure circuit is armed. (Unit Flame failure Trip circuit is armed 2 seconds after any coal elevation is put into service. i.e. any feeder proven
RC FEEDER INTERLOCK & PROTECTION 23
AND LOGIC
UNIT FLAME FAILURE TRIP SIGNAL

SADC CONTROL Secondary Air Damper Control includes both auxiliary & fuel air Damper control

SADC CONTROL A) Auxiliary Air Damper Control: Auxiliary air damper position at above & below 30% boiler load. Auxiliary Air Damper Position
Boiler load<30%(opening) Boiler load>30%(closing)
1) When boiler load below 1) Auxiliary air dampers 30% MCR all auxiliary air associated with non dampers are opened 100% service elevation will close from top to bottom with 10secs time sequence 2) Furnace to Wind box DP is 2) Furnace to Wind box DP is maintained approximately increased with respect to 40mmwc oil header pressure.
Note: During furnace purge, all auxiliary air dampers are in 100% open condition
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SADC CONTROL A) Auxiliary Air Damper Control:
1)Conditions leading to Manual control & automatically open of Auxiliary Air Damper All ID fans OFF All FD fans OFF MFT Loss of 24V DC
OR Logic Commanded to 100% open + Manual control
2) Conditions leading to Manual control : DP trans. deviation very high Failure of selected DP trans. Furnace to Wind Box DP very High >240mmwc
OR Logic
Thrown to Manual control

SADC CONTROL B) Fuel(Coal) Air Damper Control: Fuel air dampers are modulated with respect to feeder rate
Feeder ON signal
50 seconds >
OPEN cmd to fuel air damper CLOSE cmd to fuel air damper
Feeder OFF signal
50 seconds >
Note: During purging all fuel air dampers are in 100% open position.

SADC CONTROL B) Fuel(Coal) Air Damper Control: 1)Conditions leading to Manual control & automatically open of Fuel Air Damper: All ID fans OFF All FD fans OFF MFT Loss of 24V DC 2) Conditions leading to Manual control : Feeder rate signal failed open cmd from FSSS close cmd from FSSS
OR Logic Thrown to Manual control OR Logic Commanded to 100% open + Manual control

SADC CONTROL C) Over fire Air Damper Control: Over fire air dampers are used to control SOx & NOX 1. 2. Lower Over fire air damper will open when boiler load >50% MCR Upper Over fire air damper will open when boiler load>75%MCR
BOILER AUXILIARIES INTERLOCK & PROTECTION
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ID FANS INTERLOCKS & PROTECTION Conditions existing when the unit is shutdown and prior to starting of ID Fans: 1) ID fan A & B are OFF. 2) Regulating dampers of fans A & B are fully open. 3) Inlet gates of ID fans A & B open. 4) Outlet gates of ID fans A & B open.
5) The regulating dampers and hydraulic coupling will be on manual control

during shutdown and impulse from furnace draft control to regulating dampers of ID fans disconnected.
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ID FANS INTERLOCKS & PROTECTION Starting of ID Fan A (ID Fan B is OFF): A) ID fan A shall be prohibited from starting till the following conditions are satisfied: 1) Regulating dampers of ID FAN - A in minimum position. 2) Hydraulic coupling scoop tube for ID FAN - A in minimum position & manual. 3) Outlet gate of ID FAN A closed. 4) Intel gate of ID FAN A closed.
5) ID FAN - As fan & motor bearing temperature not very high.

6) Motor winding temperature not very high. 7) One of APH is running with its inlet & Outlet dampers in open position.
8) Lube oil permissive satisfied(any LOP on & pressure >0.8 ata).

9) Hydraulic coupling of ID Fan-As oil level O.K and cooler ready for operation. 10)Flue gas path available(dampers across APH,ESP & FD fan o/l damper open).
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ID FANS INTERLOCKS & PROTECTION Starting of ID Fan A (ID Fan B is OFF): B) When ID fan A is started , impulses shall be given for :1) Opening the inlet gate of ID Fan- A after the motor reaches rated speed. 2) Connecting the regulating dampers/scoop tube control of ID Fan A to auto control 3) Closing the inlet gate and the outlet gate of ID Fan B and bring the
regulating dampers/scoop tube control to minimum position

4) Permission to start either FD Fan A or B
*Same similar interlocks for Starting ID Fan B (ID Fan A is OFF)
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ID FANS INTERLOCKS & PROTECTION Tripping of ID Fan A (ID Fan B is OFF): A) ID fan A will trip automatically under following conditions:ID fan As fan bearing temp too high>90c >10secs ID fan As motor bearing temp too high>90c >10secs ID fan As motor winding temp too high>130c >10secs ID fan As fan(12.6mm/sec) or Motor(9.6mm/sec) vibration too high>10sec FD fans tripping interlock to ID fan ID fan A ON & its I/T gate closed>30secs OR LOGIC Trip signal to ID fan A
ID fan As working oil temp very high>110c>2secs

ID fan As motor protection, eg- earth fault, short-circuit
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ID FANS INTERLOCKS & PROTECTION Tripping of ID Fan A (ID Fan B is OFF): B) When ID fan A trips simultaneous impulse will be give for :1) Tripping signal to working FD fan. 2) Tripping signal to Boiler through FSSS. 3) Disconnecting the impulse from auto control to regulating damper and Hydraulic coupling control.
4) Opening of inlet & outlet gate of ID fan B.

5) Commanded to wide open of regulating damper of ID A & B.
*Same similar interlocks for ID Fan B(ID Fan A is OFF)
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ID FANS INTERLOCKS & PROTECTION Starting of ID Fan B (ID Fan A is ON): A) ID fan B shall be prohibited from starting till the following conditions are satisfied: 1) Regulating dampers of ID FAN - B in minimum position. 2) Hydraulic coupling scoop tube for ID FAN - B in minimum position & manual. 3) Outlet gate of ID FAN B closed. 4) Intel gate of ID FAN B closed.
5) ID FAN - Bs fan & motor bearing temperature not very high.

6) ID FAN - Bs Motor winding temperature not very high. 7) Lube oil permissive satisfied(any LOP on & pressure >0.8 ata).
8) ID Fan-Bs Hydraulic coupling oil level O.K.
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ID FANS INTERLOCKS & PROTECTION Starting of ID Fan B (ID Fan A is ON): B) When ID fan B is started (ID fan A is ON), impulses shall be given for :1) Opening the inlet gate of ID Fan- B after the motor reaches rated speed. 2) Connecting the regulating dampers/scoop tube control of ID Fan B to auto control 3) Permission to start another FD Fan.
*Same similar interlocks for Starting ID Fan A (ID Fan B is ON)
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ID FANS INTERLOCKS & PROTECTION Tripping of ID Fan B (ID Fan A is ON): A) ID fan B will trip automatically under following conditions:ID fan Bs fan bearing temp too high> 90c >10sec
ID fan Bs motor bearing temp too high> 90c >10sec

ID fan Bs motor winding temp too high130c>10sec ID fan Bs fan (12.6mm/sec) or Motor(9.6mm/sec) vibration too high>10sec FD fans tripping interlock to ID fan ID fan B ON and I/T gate not open>30sec ID fan Bs hydraulic coupling lub oil pressure very low<0.6Bar OR LOGIC Trip signal to ID fan B
ID fan Bs hydraulic coupling working oil temp very high>110c for 2sec ID fan Bs motor protection, eg- earth fault, short circuit RC FEEDER INTERLOCK & PROTECTION
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ID FANS INTERLOCKS & PROTECTION Tripping of ID Fan B (ID Fan A is ON or vise versa): B) When ID fan B trips simultaneous impulse will be give for :1) Disconnecting the impulse from auto control to regulating damper and Hydraulic coupling control. 2) Bring the regulating damper of ID fan B to minimum position. 3) Bring the hydraulic coupling scoop tube position to minimum.
4) Commanded to close inlet & outlet gate of ID fan B.

5) Tripping signal to one working FD fan( 2 FD fans working). 6) Initialization of Partial load relay to reduce boiler load to 60%MCR.
*Same similar interlocks for ID Fan A(ID Fan B is ON)
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ID FANS LUBRICATION OIL PUMPS: There are 2x100% LOPs(1W, 1S) are provided for each ID fans
LOPs will automatically start under following condition(when ID A is ON):

LOP A tripped
LOP A is ON & pressure<0.6ATA
>30secs
>30secs
OR LOGIC
OR LOGIC
START CMD TO LOP B
LOP B tripped LOP B is ON & pressure<0.6ATA
>30secs >30secs
START CMD TO LOP A
LOP A or B will automatically stop under following condition(when both LOPs are ON):
LOP A ON LOP B ON Lub Oil pressure>0.8ATA
AND
>5secs LOGIC
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TRIP CMD TO ANY ONE LOP A or B
*same similar interlocks for ID INTERLOCK fan Bs&LOPs RC FEEDER PROTECTION

FD FANS INTERLOCKS & PROTECTION Conditions existing when the unit is shutdown and prior to starting of FD Fans: 1) FD fan A & B are OFF 2) FD fan A & B blade pitch in maximum position. 3) FD fan blade pitch control disconnected. 4) Lub Oil pumps of FD fans off.
5) Outlet dampers are fully open.
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FD FANS INTERLOCKS & PROTECTION Starting of FD Fan A (FD Fan B is OFF): A)FD fan A shall be prohibited from starting till the following conditions are satisfied: 1) ID fan either A or B is ON. 2) FD FAN A blade pitch control in minimum position. 3) Outlet damper of FD FAN A closed 4) Intel gate of FD FAN A open
5) FD FAN - As fan & motor bearing temperature not very high

6) Motor winding temperature not very high 7) FD fans Lube oil permissive satisfied(any LOP on & pressure >13bar)
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FD FANS INTERLOCKS & PROTECTION Starting of FD Fan A (FD Fan B is OFF): B) When FD fan A is started (FD fan B is off), impulses shall be given for :1) Opening the outlet gate of FD Fan- A after the motor reaches rated speed. 2) Outlet damper of FD Fan B to close & impeller blades of FAN-B to be driven to minimum position. 3) Connecting the blade pitch control of Fan A to auto control.
*Same similar interlocks for Starting FD Fan B (FD Fan B is OFF)
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FD FANS INTERLOCKS & PROTECTION Tripping of FD Fan A (FD Fan B is OFF): A) FD fan A will trip automatically under following conditions:FD fan As fan bearing temp too high> 105c >10sec FD fan As motor bearing temp too high> 110c >10sec FD fan As motor winding temp too high> 130c >10sec FD fan As fan(12.6mm/sec) or Motor(9.6mm/sec) vibration too high>10sec ID fan trips FD fan A ON and its O/T gate not open>120sec OR LOGIC Trip signal to FD fan A
FD fan As motor protection, eg- earth fault, short circuit
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FD FANS INTERLOCKS & PROTECTION Tripping of FD Fan A (FD Fan B is OFF): B) When FD fan A trips simultaneous impulse will be give for :1) Disconnecting the blade pitch of FD fan A & B to the maximum. 2) Opening the outlet damper of fan B. 3) To open the scanner air emergency suction damper. 4) Tripping signal to Boiler through FSSS
5) The outlet damper of FD fan A shall remain open.

*Same similar interlocks for FD Fan B(FD Fan A is OFF)
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FD FANS INTERLOCKS & PROTECTION Starting of FD Fan B (FD Fan A is ON): A)FD fan B shall be prohibited from starting till the following conditions are satisfied: 1) Two ID fans should be ON. 2) FD FAN B blade pitch control in minimum position. 3) Outlet damper of FD FAN B is in closed position. 4) FD FAN - Bs fan & motor bearing temperature not very high
5) Motor winding temperature not very high

6) FD fans Lube oil permissive satisfied(any LOP on & pressure >3BAR)
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FD FANS INTERLOCKS & PROTECTION Starting of FD Fan B (FD Fan A is ON): B) When FD fan B is started (FD fan A is on), impulses shall be given for :1) Opening of outlet damper of FD Fan- B after the motor reaches rated speed. 2) Connecting the blade pitch control of Fan B to auto control.
*Same similar interlocks for Starting FD Fan A (FD Fan B is OFF)

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FD FANS INTERLOCKS & PROTECTION Tripping of FD Fan B (FD Fan A is ON): A) FD fan B will trip automatically under following conditions:FD fan Bs fan bearing temp too high> 105c >10sec FD fan Bs motor bearing temp too high> 110c >10sec FD fan Bs motor winding temp too high> 130c >10sec
FD fan Bs fan(12.6mm/sec) or Motor(9.6mm/sec) vibration too high>10sec

Any one or both ID fan trips FD fan B ON and its O/T gate not open>120sec FD fan Bs motor protection, eg- earth fault, short circuit
OR LOGIC
Trip
signal to FD fan B
48

FD FANS INTERLOCKS & PROTECTION Tripping of FD Fan B (FD Fan A is ON): B) When FD fan B trips simultaneous impulse will be give for :1) Disconnecting FD fan B the blade pitch control from auto. 2) Bringing the FD fan B blade pitch control to minimum position. 3) Closing the outlet damper of Fan B. 4) Initiation of partial load relay for 60% MCR
*Same similar interlocks for FD Fan A trips (FD Fan B is OFF)
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FD FANS LUBRICATION OIL PUMPS: There are 2x100% LOPs(1W, 1S) are provided for each FD fans LOP will automatically start under following condition(when FD A is ON):
LOP A tripped
LOP A is ON & pressure<9BAR
>30secs
>60secs
OR LOGIC
OR LOGIC
START CMD TO LOP B
LOP B tripped LOP B is ON & pressure<9BAR
>30secs >30secs
START CMD TO LOP A
LOP will automatically stop under following condition(when both LOPs are ON):
LOP A ON LOP B ON Lub Oil pressure>13BAR
AND
>5secs LOGIC
50
RC FEEDER INTERLOCK & PROTECTION *same similar interlocks for FD fan Bs LOPs

PA FANS INTERLOCKS & PROTECTION Conditions existing when the unit is shutdown and prior to starting of PA Fans: 1) PA fan A & B are OFF 2) PA fan A & B blade pitch in maximum position. 3) PA fans blade pitch control disconnected. 4) Lub Oil pumps of PA fans off.
5) Outlet dampers are fully open for PA Fan A & PA Fan B.
51

PA FANS INTERLOCKS & PROTECTION Starting of PA Fan A (PA Fan B is OFF): A)PA fan A shall be prohibited from starting till the following conditions are satisfied: 1) Either FD fan A or B is ON. 2) PA FAN A blade pitch control in minimum position. 3) Purge completed 4) PA FAN - As fan & motor bearing temperature not very high
5) Motor winding temperature not very high.

6) APH should be in service with one gas & air inlet and outlet damper opened. 7) PA fans Lube oil permissive satisfied(any LOP on & pressure >0.8 ata)
52

PA FANS INTERLOCKS & PROTECTION Starting of PA Fan A (PA Fan B is OFF): B) When PA fan A is started , impulses shall be given for :1) Opening the outlet damper of PA Fan- A. 2) Connecting the blade pitch control of PA Fan A to auto control 3) Bringing the blade pitch of PA fan B to minimum position. 4) Closing of outlet damper of PA fan B
5) Permission to start 3 lower coal elevations through FSSS
*Same similar interlocks for Starting PA Fan B (PA Fan A is OFF)
53

PA FANS INTERLOCKS & PROTECTION Tripping of PA Fan A (PA Fan B is OFF): A) PA fan A will trip automatically under following conditions:PA fan As fan bearing temp too high> 105c >10sec PA fan As motor bearing temp too high> 90c >10sec PA fan As motor winding temp too high>120c >10sec
PA fan As fan(12.6mm/sec) or Motor(9.6mm/sec) vibration too high>10sec

Both FD fan trips PA fan A ON and its O/T gate not open>120sec PA fan As motor protection, eg- earth fault, short circuit MFT acted
OR LOGIC
Trip signal to PA fan A
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PA FANS INTERLOCKS & PROTECTION Tripping of PA Fan A (PA Fan B is OFF): B) When PA Fan B trips simultaneous impulse will be give for :1) Disconnecting the blade pitch control from auto. 2) Bringing the PA fan A blade pitch control to minimum position. 3) Closing the outlet damper of PA Fan A. 4) Tripping all the operating mills (through FSSS)
*Same similar interlocks for PA Fan B(PA Fan A is OFF)
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PA FANS INTERLOCKS & PROTECTION Starting of PA Fan B (PA Fan A is ON): A) PA fan B shall be prohibited from starting unless following condition are satisfied 1) Both FD fans ON. 2) Blade pitch control of PA fan B in min. condition. 3) PA fan B & Motor bearing temp not very high(<90oC) 4) Motor winding temp. not very high(<80oC).
5) Both APH are running with their gas and air inlet and outlet dampers opened
6) Lube oil permissives satisfied *Same similar interlocks for Starting PA Fan B (PA Fan A is ON)
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PA FANS INTERLOCKS & PROTECTION Starting of PA Fan B (PA Fan A is ON): B) When PA fan B is started (PA fan A is ON), impulses shall be given for :1) Opening the outlet damper of PA fan B after the motor ON (TD = 30 sec.). 2) Connecting the damper control of PA fan B to auto control. 3) Permission to put in service remaining coal elevation through FSSS.
*Same similar interlocks for Starting PA Fan A (PA Fan B is ON)
57

PA FANS INTERLOCKS & PROTECTION Tripping of PA Fan B (PA Fan A is ON): A) PA fan B will trip automatically under following conditions:PA fan Bs fan bearing temp too high> 105c >10sec PA fan Bs motor bearing temp too high> 90c >10sec PA fan Bs motor winding temp too high>120c >10sec PA fan Bs fan(12.6mm/sec) or Motor(9.6mm/sec) vibration too high>10sec Both FD fans OFF OR LOGIC Trip signal to PA fan B
PA fan B ON and its O/T gate not open>120sec PA fan Bs motor protection eg- earth fault, short circuit MFT acted
58

PA FANS INTERLOCKS & PROTECTION Tripping of PA Fan B (PA Fan A is ON): B)When PA Fan B trips simultaneous impulse will be give for :1) Disconnecting the blade pitch control of PA fan B from auto. 2) Bringing the PA fan B blade pitch control to minimum position. 3) Closing the outlet damper of PA Fan B. 4) Initiation of partial load relay for 60% MCR
*Same similar tripping interlocks for PA Fan A(PA Fan B is ON)
59

PA FANS LUBRICATION OIL PUMPS: There are 2x100% LOPs(1W, 1S) are provided for each PA fans
LOP will automatically start under following condition(when PD A is ON):

LOP A tripped
LOP A is ON & pressure<13BAR
>30secs
>30secs
OR LOGIC
OR LOGIC
START CMD TO LOP B
LOP B tripped LOP B is ON & pressure<13BAR
>30secs >30secs
START CMD TO LOP A
LOP will automatically stop under following condition(when both LOPs are ON):
LOP A ON LOP B ON Lub Oil pressure>20BAR
AND
>5secs LOGIC
60
RC FEEDER INTERLOCK & PROTECTION *same similar interlocks for PA fan Bs LOPs

APHs INTERLOCKS & PROTECTION Conditions existing when the unit is shutdown and prior to starting of APH: 1) All AHs are off (both electric motor and air motor). 2) The inlet and outlet dampers of flue gas path, Secondary Air path, Primary Air path are in full open condition. Starting Air Heater A (Air Heater B is OFF) One electric motor and one air motor have been provided for APH drive system. 1) Air Heater A electric main motor is started if the sump oil temperature of the bearings measured through RTD is less than 70oC 2) Impulse shall be given for closing of the inlet and outlet dampers for air & gas side of Air Heater B which is off *same similar interlocks for starting APH B(APH A is OFF)

APHs INTERLOCKS & PROTECTION Tripping of APH-A (APH-B is OFF): 1) APH electric motor fault. 2) Whenever the sump oil temperature of support/guide bearing is greater than 70oC an alarm shall be initiated through RTD to the operator. The operator shall check the circulation pump operation & the coolant flow at local to bring down the sump oil temperature. In case if the temperature of sump oil is unable to be brought down, APH electric motor/air motor shall be tripped manually. When APHs electric motor trips simultaneous impulse will be give for :1) To start Air motor with 5 secs delay
*same similar interlocks for starting APH B(APH A is OFF)


APHs INTERLOCKS & PROTECTION Tripping of APH-A (APH-B is ON) or vise versa: 1) Gas I/L & O/T damper, Secondary air O/T damper, and PA I/L & O/T damper of the tripped AH shall be automatically closed. 2) Boiler load reduced approx 60 %MCR
Tripping of both APH A & B 1) Operator may try for restarting the APHs. 2) If any one of the APH is not started within 5 minutes the operator shall manually trip the boiler. 3) All Gas I/L & O/T damper, Secondary air O/T damper, and PA I/L & O/T damper should be opened

APHs INTERLOCKS & PROTECTION Interlocks for Oil Circulation Pumps of support bearings(SB) of Air heaters: 2 x 100% oil circulation pump have been provided for the support bearing. Anyone of the two oil circulation pumps can be pre selected as main pump and the other as standby. Following interlocks shall be provided for Oil Circulating Pumps
APH ON AND
SB LOP1 OFF>2SEC
APH ON SB LOP1 ON LOW FLOW>30SECS
OR AND
START CMD TO OTHER LOP

APHs INTERLOCKS & PROTECTION Interlocks for Oil Circulation Pumps of guide bearings(GB) of Air heaters: 2 x 100% oil circulation pump have been provided for the guide bearing. Anyone of the two oil circulation pumps can be pre selected as main pump and the other as standby. Following interlocks shall be provided for Oil Circulating Pumps
APH ON AND
GB LOP OFF>2SEC
APH ON GB LOP1 ON LOW FLOW>30SECS
OR AND
START CMD TO OTHER LOP

PULVERISER INTERLOCKS & PROTECTION Conditions existing when the unit is shutdown and prior to starting of MILL: 1) Mill Motor off 2) LOPs for Mills off

PULVERISER INTERLOCKS & PROTECTION Starting of Mill: A)MILL shall be prohibited from starting till the following conditions are satisfied:
1) Bunker Outlet Gate open 2) Feeder Inlet Gate open 3) Mill Discharge valves open(4nos)
4) Seal air valve is open

5) 6) 7) 8) 9) Mill start permit from Pulveriser Lub Oil System Mill outlet temp not high <94C Cold air Gate open Tramp Iron Hopper Valve open Mill/Oil elevation start permit.
10) Nozzle tilts placed in the horizontal position(for 1st pulveriser only). 11) Primary air pressure is adequate(>650mmwc) 12) Pulveriser Bowl DP Adequate >200 mmwc 13) MILL status off & ignition permit available

PULVERISER INTERLOCKS & PROTECTION Starting of Mill: B) When MILL is started, impulses shall be given for :1) Permission to open the hot air gate(HAG) & impulse to regulate HAG 2) Permission to start the Raw Coal Feeder.
*Same similar interlocks for Starting all other Mills


PULVERISER INTERLOCKS & PROTECTION Tripping of Mill: A) Mill will trip automatically under following conditions:Motor winding temperature too high>130oC >5sec
Motor bearing temperature too high>85oC >5sec

Mill bearing temperature too high> 90oC>5sec Mill vibration too high>9mm/s> 15 sec Mill trip from Pulveriser Lub Oil System(PLOS) Mill discharge damper not open MFT acted Both PA fans trips Ignition energy disappears before 180 secs from feeder start Seal air header pressure very low>60secs
OR LOGIC
Trip
signal to Mill motor

PULVERISER INTERLOCKS & PROTECTION Tripping of MILL: B) When MILL is tripped, simultaneous impulses shall be given for :1) Signal to trip the feeders motor 2) To close the hot air gate. 3) To bring cold air damper to minimum position
*Same similar interlocks for other Mill tripping.


RAW COAL(RC) FEEDER INTERLOCKS & PROTECTION RC Feeder Starting: A) RC Feeder motor is prohibited from starting till the following conditions are satisfied: 1) No boiler trip condition prevails. 2) Elevation AC&DC available 3) Ignitor energy is available 4) Pulveriser is ON 5) Hot air gate is open

RC FEEDER INTERLOCKS & PROTECTION RC Feeder Starting: B) RC Feeder motor is simultaneous impulse shall be give for : 1) To include feeder output in totalizing circuit after 15secs 2) To release feeder speed control to auto after 50secs 3) To modulate fuel air dampers according to feeder speed after 50secs

RC FEEDER INTERLOCKS & PROTECTION Tripping of RC feeder motor: RC feeder motor will trip automatically under following conditions:Boiler Trips
Elevation DC fails >2secs Elevation AC fails
Pulveriser trips
RC motors electrical trip Loss of coal flow & pulveriser amps low
OR LOGIC
Trip signal to RC motor
Ignition energy disappears before 180 secs from feeder start
73

REHEATER PROTECTION This protection is provided to protect the Reheater against starvation of steam flow during abnormal conditions. To take care of Reheater protection, the Boiler shall be tripped after 10 seconds, when any of the following conditions occur. Reheater protection will armed automatically under following conditions:
DRUM PRESSURE >8ata ANY FEEDER ON OR
BOILER FIRING SIGNAL FROM FSSS
AND LOGIC
REHEATER PROTECTION ARMED
LOGIC
74

REHEATER PROTECTION Reheater protection will automatically enable under following conditions:
GENERATOR CKT BREAKER OPENED

AND
HPBP OR LPBP OPENED<2%
LOGIC
REHEATER PROT ARMEND
OR
IF ANY OF 1 OR MORE VALVES CLOSED 1. HPSV1 5. IPSV1 2. HPCV1 6. IPCV1 3. HPSV2 7. IPSV2 4. HPCV2 8. IPCV2 HPBP OR LPBP OPENED<2% AND
10SEC >
REHEATER PROTECTION ACTED(Boiler Trip)
LOGIC
LOGIC
REHEATER PROT ARMEND

75
T H A N K S
76

1 RC Feeder Interlock & Protection

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1 RC Feeder Interlock & Protection

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RC FEEDER INTERLOCK & PROTECTION

RC FEEDER INTERLOCK & PROTECTION

Furnace Safeguard Supervisory System(FSSS)

start up and shutdown of fuel firing equipments and to prevent error of

RC FEEDER INTERLOCK & PROTECTION

FSSS is designed to perform the following functions:

interlocks have first been satisfied.

FSSSs Operational Function:

FSSSs Operational Function:

Press START PURGE button

5 minute count down timer ON RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

Light oil trip valve is proven closed.

RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

FSSSs Operational Function:

HOTV OPEN permissive satisfied

To AB,CD,EF elevation burners

RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

HO Recirculation valve is not closed

CLOSE command to HOTV

HO header pressure very low

Any HO nozzle valve not closed

HO header temperature very low Any HO nozzle valve not closed

*Also HO commanded to close under loss of 220VDC

FSSSs Operational Function:

11 RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

Permit signal to start PULVERISER B

Permit signal to start PULVERISER C

FSSSs Operational Function:

Permit signal to start PULVERISER E

Permit signal to start PULVERISER F

13 RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

PULVERISER AUTO START

OPEN COMMAND TO HOT AIR GATE

MANUAL MODE OPEN HAG FROM PUSH BOTTON

CONDITIONS FOR HAG

14 RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

15 RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

3. Both FD Fans off.

7. Furnace pressure very high.

FSSSs Operational Function:

4) Tripping all the feeders.

17 RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

18 RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

2)DC scanner fan will automatically start:

RC FEEDER INTERLOCK & PROTECTION

FSSSs Operational Function:

AND ELE AB FLAME LOGIC

Arming signal to FLAME FAILURE TRIP PROTECTION

*Same similar flame indication logic for BC,CD,DE,EF