A

Presentation on
Boiler
& Rajesh Kumar Biswal
Mobile: 7052006777
it’s Auxiliary Protections [email protected]

Jindal Power Limited, Tamnar

Importance:

❑ The steam generators supplied today are larger in size and sophisticated in
nature. Failure of any equipment calls for expensive replacement and
results in costlier down time. This emphasizes careful planning on the
correct procedure for;

➢ Safe sequence of start-up of equipment in the power plant.

➢ Continuous trouble free & efficient operation.

➢ Safe sequence of shutdown of the equipment when needed.

Interlock:

❖ An interlock is a feature that makes controls machines or devices so that

their operation is interdependent in order to assure that they are
coordinated properly.

.
Permissive:
❖ A permissive is a specific type of interlock used to prevent actions from
taking place until certain criteria are met.

❖ A condition within a logic sequence that must be satisfied before the

sequence is allowed to proceed to the next phase.
Protection of boiler:
Boiler protection are provide to detect the abnormal condition by constantly
measuring the various parameter under normal and faulty condition. If any
abnormality happened trip the boiler to prevent from major damage

Need of Interlocks & Protection:

❖ To avoid operational faults

❖ To avoid equipment damage.

❖ To avoid accidents to individuals.

❖ To avoid system disturbances

 PROTECTIONS ARE CLASSIFIED UNDER THREE GROUPS NAMELY:

1) Protection causing complete shut down of the unit.

2) Protection causing load reduction of the unit.

3) Protection causing annunciation only.

Protection causing complete shut down of the unit.:

Example: Failure of all feed pumps
Boiler shutdown due to failure of both FD fans, both ID fans
Protection causing load reduction of the unit.
Example: One ID fan trip
One FD fan Trip
One Mill trip
Protection causing annunciation only.
Any abnormalities when the system is service gives us warning alarm .
 An Overview on FSSS
▪ The system provided is known as FURNACE SAFEGUARD AND
SUPERVISORY SYSTEM abbreviated as FSSS.

▪ FSSS facilitates remote, manual/automatic control of fuel firing equipment

through mechanized system and suitable interlocks/logics

▪ Furnace safeguard Supervisory System is designed to ensure the

execution of safe, orderly operating sequence in start up and shutdown of
fuel firing equipment and to prevent any damage to equipment due to
human errors or equipment mal operation.

▪ The system provides protection against malfunction of fuel firing

equipment and associated air system

▪ The safety feature of system are designed for protection in most common
emergency situations.
 FURNACE PURGE
Purpose:
▪ Complete removal of un-burnt fuel from entire furnace

Procedure:
▪ Ensure that all fuel to furnace is cut off and all flame is out
▪ Provide adequate air flow through furnace (30 to 40%)
▪ Initiate a mandatory purge time cycle (540 seconds)

Consequence:
▪ Master fuel trip relays are reset
▪ Firing of fuel into the furnace is allowed
 PURGE PERMISSIVE

• No boiler trip
• LOTV closed
• All LONV closed
. • All PA fans OFF

• ALL coal feeders OFF

• All HAG closed
. • All Aux. air dampers modulating

• Air flow > 30% and < 40 %

• All scanners show no flame
. • MFT DPU not frozen
FURNACE PURGE
 Purge Cycle
❑ The furnace purge cycle is started by pressing purge start push
button.

❑ A 540 second purge timer is energized as indicated by the

"purging" light coming on.

❑ At the end of the 540 second , the boiler trip circuit is reset,
provided no boiler trip command is present.
❑ The "purging" light goes out and "purge complete” light comes
on.
❑ Once the boiler trip circuit is reset, purging is complete

❑ If any of the permissive goes missing during purging purge

process is stopped and “purge Interrupted” light comes on

❑ After acquiring the missing permissive purge has to be restart

from the very beginning .
CORNER FIRING SYSTEM
TANGENTIAL BURNER-TOP VIEW
(CORNER FIRING)
 BOILER PROTECTIONS

SL No. PROTECTION DESCRIPTION ALARM TRIP TIME REMARKS

VALUE VALUE DELAY

1 Both ID Fans Off 3 hardwired contacts

For each ID Fan(2/3)

2 Both FD Fans Off

3 Water wall circulation <10 psi 5 sec

not correct
4 UCP:EMGPB Press
Together
5 Any OWS: EMG trip
Command Initiated
6 Furnace Pressure very -100 mmwc -175 mmwc 2/3 pr. switch
low
7 Furnace Pressure very +75 mmwc +150 mmwc 2/3 drum level tx
high
8 Drum level very low -175 mm -375 mm 5 sec 2/3 drum level tx

9 Drum Level very high +125 mm +250 mm 10 sec

 BOILER PROTECTIONS
SL PROTECTION DESCRIPTION TRIP TIME REMARKS
No. VALUE DELAY

10 Total Air Flow<25% < 600 tph 100%=Total airflow

At BMCR=2378TPH
11 Loss of Reheater
Protection acted
12 Unit220V DC Not available

13 Unit24 VDC Not Available

14 <FB & loss of 110 V AC for nozzle

110V AC in any Valve solenoids
Elevation In service Arming: All feeders
off
15 Unit flame failure trip Arming: Any feeder
activate proven

16 Loss of All Fuel Trip Arming : Any LO

activated Nozzle valve not
closed
17 Both Air Heaters Off
18 All BFP tripped
 LOSS OF BOTH I.D. FANS
➢ Both id fans off 3 hardwired contacts for each ID
fan (2/3) (ht switchgear)
Purpose:
 Anticipatory protection to prevent furnace pressurization

 Loss of furnace pressure control and balanced draft.

Cause
Fan trips due to any of the reasons
✓ Unit Auxiliary bus supply failed
✓ One ID fan tripped on one of the following reasons and second ID fan trips on
Over load
✓ Electrical motor protection
✓ Fan brg. Temp. Hi hi
✓ Motor brg. Temp. Hi hi
Effect:
✓ Unit will trip on loss of both I.D.Fan.
✓ Both ID fans discharge and suction dampers wide open
Action
✓ Start ID fan by taking corrective action.
 LOSS OF BOTH F.D. FANS
➢Both fd fans off 3 hardwired contacts for each fd
fan (2/3) (ht switchgear)
Importance:
In order to avoid furnace implosion/collapsing inward
Cause
Fan trips due to any of the reasons
✓ Unit Aux supply failed
✓ One FD fan has tripped on one of the following reasons and
second FD fan trips on Over load.
✓ Electrical motor protection
✓ Fan brg. Temp. Hi hi
✓ Motor brg. Temp. Hi hi
✓ Loss of lubrication
✓ Loss of cooling water to lubricating oil cooler
✓ Corresponding I.D. Fan tripping
Effect
✓ Unit trips on both FD fan trip
Action
✓ Restart FD fans after removing cause of tripping.
 Water wall circulation not correct
Importance:
❑ In order to avoid Water tube starvation
❑ Ensure proper circulation ratio:

Cause
✓ BWC tripped for any reason
✓ Cavity temp high.
✓ High current
✓ Suction dis. DP not maintained. BCW DP < 0.68 ksc

Effect:
➢ Boiler will be tripped
➢ Boiler Water tube starvation
➢ Drum level high and water carry over
➢ Preventing DNB

Action:
Find the reason of tripping and restart the pumps
 FURNACE DRAUGHT VERY HIGH

➢ Furnace pressure high alarm at +75 mmwc

➢ Furnace pressure very high boiler trip at +150 mmwc 2/3 pressure
switches
Importance:

➢ To stop fuel firing under implosive tendency of furnace.

➢ Prevent furnace structural distortion

Cause:
✓ Faulty operation of ID fan vane control

✓ Disturbed combustion(Mill Overfeed)

✓ Un controlled fuel entry

✓ Sudden falling clinkers in furnace

✓ Soot blowing in progress

✓ Burner tilt not in synchronism

✓ Gas path damper closed

 FURNACE DRAUGHT VERY HIGH
EFFECT
✓ Unit will trip if variation is more
✓ Variation in drum level
✓ Bottom ash hopper water splashing
✓ Flame coming out from various pip holes may damage equipment / Cables
ACTION
✓ Take ID or FD fan control on manual / local
✓ Disturbed combustion due to mill trouble, take oil support, check flame
condition
✓ Adjust burner tilt in synchronism
✓ If furnace draft has increased beyond the limit, boiler will trip.
✓ Always operate the soot blower at higher load.
✓ If soot blowing is in operation, stop it.
✓ Check that gas path dampers are open
 FURNACE DRAUGHT VERY LOW
➢ FURNACE PRESSURE LOW ALARM AT -100 MMWC

➢ FURNACE PRESSURE VERY LOW BOILER TRIP AT -175 MMWC 2/3

PRESSURE SWITCHES
Importance:
➢ To stop fuel firing under implosive tendency of furnace.

➢ Prevent furnace structural distortion

Cause:
✓ FD fan vane closed
✓ Disturbed combustion : Mill tripped
✓ Clinker fallen
✓ Soot blowing in operation
✓ Burner tilt not in synchronism
 FURNACE DRAUGHT VERY LOW

EFFECT

✓ Unit may trip on Furnace draft very low

✓ Variation in drum level

ACTION

✓ Adjust FD fan vane manually / locally

✓ Introduce oil support
✓ Close HAG of troubled mill
✓ Stop soot blowing if in operation
✓ If draft variation will reach trip value, unit will trip
 DRUM LEVEL VERY LOW
➢ Drum level low alarm at -175mm

➢ Drum level v.Low at -375 mm & time delay 5 sec 2/3 transmitter
Importance:
❑ To prevent water wall tubes starvation
❑ To prevent BCW pumps starvation

Effect
✓ Boiler will trip / Damage may occur if protection bypassed

Cause
✓ Running BFP tripped and Stand By BFP did not start on
Auto/Manual
✓ Feed control valve stuck up
✓ Boiler tube leak
✓ Sharp increase in load
✓ Furnace draft variation
 DRUM LEVEL VERY LOW

ACTION
✓ Attempt to control with feed control valve on “Manual”

✓ If the feed control valve is stuck up, open stand by line valve

✓ Take care while increasing feed flow to avoid running BFP from

tripping.

✓ If running BFP tripped, Start S/B BFP immediately.

✓ If drum level decreases below the limit, allow the unit to trip
 DRUM LEVEL VERY HIGH
➢ Drum level high alarm at +125mm

➢ Drum level V.High at +250 mm & time delay of 10 sec 2/3

transmitter

Importance:
To prevent water carry over to super heater headers and subsequently to turbine

Effect
✓ Water may enter turbine and serious damage to turbine may occur
(Deposition)

Cause
✓ Failure of drum level controller
✓ Extra ordinary increase in load
✓ Sudden decrease in firing rate
 DRUM LEVEL VERY HIGH
✓ Joints & valves on steam line may leaks(Hammering)
✓ Carry over with sharp fall in steam temperatures will follow turbine
vibration
✓ Super Heater may fail
ACTION:
✓ If drum level is within safe limits

✓ Attempt to control with feed valves

✓ If feed control valve is stuck up, close the motorise valve.

✓ Attempt to control the rising drum level with blow down CBD &
EBD
✓ allow BFP to run in re-circulation

✓ If above measure fails, trip B.F.P.

✓ If main steam temp. drops, open steam line drains.

✓ If main steam temp. drops sharply, trip the unit.

✓ If drum level increases above the limit, allow the unit to trip
 Total Air flow <30%
Importance:
❑ Ensuring absolute minimum required quantity of air flow even during startup

❑ Preventing localized accumulation of unburnt oil during startup

TOTAL AIR FLOW VERY LOW < 30% (713 T/Hr) Flow Transmitters

➢ During boiler lit up condition air flow is maintained at 30 to 40% ,

➢ If air flow increase above 40 % then LFO start permit and HFO start permit not

available .

➢ In Any condition if air flow decrease < 30 % then boiler will trip.
 Re-heater Protection

Importance:
Preventing RH Tubes from Starvation.
Cause
 The flue gas temp. at reheater zone will go high resulting in high
metal temp when upper mills are in service and insufficient
steam flow through reheater during low load
 Sudden loss of steam flow through reheater when boiler is at
higher load.
Action
 While raising the pressure during lit up ensure sufficient steam
flow is established before gas temp. increases more than 540
deg c.
 In case of closing of HPCV, IPCV at higher load take out
pulverizer in service, starting from top & take oil support for
flame stability.
 Re-heater Protection
➢ Loss of reheat protection arming: when any of feeder proven/flue gas
temp. More than 540 deg c.
COND-1 Gen. CB Opened &

MS Press. >20 ksc RH Protection Act & BT

&
at time delay of 10 sec
HPBP or LPBP Closed <2%

COND-2 Gen . CB closed &

&
Any HPCV & HPBP < 2 %
RH Protection Act & BT
at time delay of 10 sec
Any IPCV & LPBP < 2 %
&
Re heater protection
 Loss of all fuel
➢ Loss of all fuel trip activated

Arming: Any LO/HO nozzle valve not closed

Condition
1. All feeders Off
AND
2. LOTV Not Open OR All LONV Closed

Cause
✓ Loss Of Primary Air Conditions:
✓ 1. PA HDR Pressure very low < 490mmWc
✓ 2. All PA or FD fans off and any Pulveriser on or
✓ 3. PA HDR pressure low (TD 5 sec) <600mm WC
✓ MFT” operated
Effect:
✓ All pulverizes will trip.
✓ Variation in furnace draft and drum level
 Unit Flame failure
➢ Unit flame failure trip

Arming:
Any feeder proven)

Logic
When any feeder proven & all elevation A-H voted no flame .
➢ No flame voting logic for all elevation.
1. Feeder A STOP for more than 4 sec AND
2. AB for el-a voted AB & BC for el-b voted, BC & CD for EL-C voted CD & DE for
EL-D voted DE & EF for EL-E voted and EF for EL-F voted
✓ AB EL start and loss of AC power
OR
✓ AB EL 3/4 nozzle V/V not proven & AB elevation fire ball scanner 2 /4 no
flame. On other elevation voted only point no.2 satisfied.
 FLAME INSTABILITY
CAUSE
 Only oil in service and Oil burner flame is disturbed.
 Loss of coal in any mill and HAG is open / Mill force outage
 Mill in service are at a distance and loading of mills are less than
50% (Poor ignition energy)
 Chockage of any one discharge pipe of mill in service
 Water wall tube failure
 Soot blower operation at low load.
 Falling of clinker in furnace.
 ID /FD fan vane operational problem
EFFECT
 Flame will become unstable
 Fluctuation in furnace draught
 Secondary fuel (Oil) consumption if used for flame stability
 Unit may trip on “Flame failure” or “Furnace draft high / low”.
 Increase in Fly /Bottom ash unburnt.
 FLAME INSTABILITY
ACTION
• It can be visualized by naked eye or flame intensity
• Check oil burners in service, change it, if required replace it
• Check furnace for tube failure
• Put oil support to coal burner, if the flame is not much
disturbed.
• Check the mill discharge pipes.
• Close HAG of mill in which coal interruption took place
• Adjust fuel air ratio if it is less
• Stop soot blowing operation. Operate all LRSB & WB after
stable operation.
• Keep oil support during soot blowing if required.
• When boiler load is less than 30% keep at least 3 out of 4
guns in mill elevation or if mill loading is less than 50%
adjacent mill loading should be more than 50%
• Keep close watch on oxygen %
• Maintain min. 30% of air during lit up & low load to ensure
air rich furnace
 < fire ball loss of AC

➢ Less than fire ball and loss of AC in any elevation in

service”
➢ Arming: only oil gun is in service or all feeders off
➢ condition occurs, when all the mills are not in service and there is a loss
of power supply (110 V AC-for Solenoids) at any of the elevation in
service. Under this condition as ignition energy will not be proper (no
fire ball), the LO elevation (Oil) cannot be allowed to run without
control (as there is no power supply). Hence the boiler has to be tripped
to shutdown the elevation.

All BFP OFF

Importance:
➢ Anticipatory protection for Drum Level Very Low
➢ To prevent economizer tubes starvation
 Unit 24V DC Not Available
Importance:
If 24V fails, the processors cannot execute any logic, leading to
unsafe condition.

Logic
If 24V supply to any 2 MFT panels is lost, it will initiate a hardwired MFT
protection through 220V contactor circuit
MFT net work fail
Importance:
➢ This ensures that at least 2 processors are in healthy condition at any
point of time when boiler is in service.
➢ Failure of processors leads to unsafe condition
Logic
If any 2 MFT processors out of 3 go into failed state, or if any 2 MFT
processors go into frozen output state, it will initiate MFT protection
 Unit 220V DC Not Available
Importance:
If 220V fails, backup protection for 24V failure will be unavailable.

Logic
If 220V supply to any 2 MFT panels is lost, it will initiate a soft MFT
protection through processor logic

UCP:EMGPB Press Together

Importance:
➢ This facility allows the operation desk engineer to directly trip the boiler
in case of any operational emergency eg. Boiler Tube Leakage, Furnace
excessive Clinkering, HFO oil leakage during startup, turbine related
emergencies etc.
➢ Logic
➢ If both Desk Emergency Push Buttons pressed together
➢ If MFT is confirmed through popup from any workstation PC
 All Air-heater OFF
Importance:
 Preventing poor furnace combustion due to low
secondary air temperature
 Preventing flue gas damper isolation in all air heaters

Cause
Both Secondary Air Heaters: electric motor OFF AND air
motor OFF
 Post-trip purge fans trip
Importance:
This protection safeguards furnace against furnace pressure very
high OR very low when boiler is NOT firing.

Arming
Boiler not firing fuel for 5 min (MFT may or may not be reset)

Logic
If furnace pressure very high > 150 mmwc OR very low < -175mmwc
(AND) Air Flow > 30% THEN
TRIP all ID Fans and FD Fans