Mitsubishi Boiler Control

PLAN RECORD ISO
METRIC SCREW THREDS
REVISIONS NO. DESCRIPTION (DATE)
APPROVED
CHECKED
N51-99K-N116
Revised according to owner comment after software FAT in KM. (28 Jan. 2005) KS
1 Y. Ono Y.Ono
DRAWING NO.
RP0
12 (DNV)
() 12
A4 94 A3 0 TOTAL 95 SHEETS WITH COVER

MARINE BOILER DESIGNING SEC. TURBO & MARINE MACHIN. DESIGN DEPT APPROVED CHECKED DRAWN
DAEWOO H.NO.2227 / 2228 / 2235

MAIN BOILER(MB-4E-NS2)
T. Yuki Y. Ono K. Saito

ITEM
Functional Design Specification for Boiler Control

DRAWING NO. REV.NO
CONFERRED
SCALE ORDER
K1A32/38/44
61500 G377
N51-99K-N116
MITSUBISHI HEAVY INDUSTRIES, LTD.

NAGASAKI SHIPYARD & MACHINERY WORKS DRAWN 25 Nov. 2004 ISSUED
Kongsberg Functional Design Document (KFDD) Boiler Control System DSME 2227/2228/2235
Project: Product Synopsis:
7069
This document describes the scope and functions of the Kongsberg Maritime Vessel Control System SVC delivered to the specified vessel. Functions within other systems are not described in this document. This document when as built will serve also as operator documentation together with KM standard SVC Operator Manual 1001854
Revision: Document version: Number of pages: Reason for issue For internal comments For Approval Reissue for approval Reissue for approval Made by BA OHJ SN OHJ Checked HAE HAE MS GM
Document number: Customer doc number: Contract number: Rev. A B C D E Date 28.04.2004 13.05.2004 15.07.2004 26.01.2005
0D 0.4 93
Approved HAE HAE EW OSL
Kongsberg Maritime AS
History
Revision Description of Change
A B C
For internal comments For Approval Re-issue for approval, insert comments from MHI, dated 10 July 2004 K.Saito / MHI Marine Boiler Re-issue for approval, insert comments after FAT, January 05
References
Doc No Description
1001854 / 0D / Page 2 of 93
Table of contents
1 GENERAL ITEMS ..................................................................................................5 1.1 Definitions/Abbreviations .....................................................................................5 1.2 Flowchart symbols.................................................................................................8 2 RESPONSIBILITIES ..............................................................................................9
3 BOILER GENERAL ...............................................................................................9 3.1 General ..................................................................................................................9 3.2 Burner Management ............................................................................................13 3.3 CPU Redundancy ................................................................................................13 3.4 Power Distribution...............................................................................................14 4 BURNER SEQUENCES........................................................................................15 4.1 Fuel Oil Burning..................................................................................................16 4.2 Gas burning .........................................................................................................24 4.3 Burner Auto Mode...............................................................................................29 4.4 Burner Automatic Increase/Decrease ..................................................................30 4.5 Fuel Mode Changeover .......................................................................................34 4.6 Fuel Oil Boost UP ...............................................................................................42 4.7 Nitrogen Purge of Gas Supply Lines...................................................................43 4.7.1 N2 Purging of Main Line to Vent............................................................... 44 4.7.2 N2 Purge of Gas Header to Vent ................................................................ 45 4.7.3 N2 Purge of Gas Burner to Furnace ........................................................... 46 4.7.4 N2 Purge of Gas Header & Burner to Furnace........................................... 46 4.7.5 Main Line Vent Valves .............................................................................. 48 5 BOILER CONTROL.............................................................................................49 5.1 Drum Water Level Control..................................................................................49 5.2 Main Steam Temperature Control .......................................................................51 5.3 Atomizing Steam Pressure Control .....................................................................52 5.4 Steam Purge Pressure Control .............................................................................53 5.5 FO Pump Discharge Pressure Control.................................................................54 5.6 Steam Pressure Control .......................................................................................55 5.7 Steam Dump Control ...........................................................................................62 5.8 Flame Eyes ..........................................................................................................65 5.9 FDF STBY Fan....................................................................................................66
1001854 / 0D / Page 3 of 93
5.10 5.11 5.12 5.13 6
Hot Start Valve ....................................................................................................67 Viscometer Outlet Valve .....................................................................................68 Fuel/Atomizing Valve Abnormal ........................................................................69 Output to Main Turbine.......................................................................................70 BOILER TRIP .......................................................................................................71
7 BOILER OPERATION PANELS ........................................................................78 7.1 BGB Graphic Panel .............................................................................................78 7.2 Manual Loader Functions....................................................................................82 7.3 Emergency Operation..........................................................................................84 7.3.1 No.1 or No.2 part........................................................................................ 84 7.3.2 Common Part.............................................................................................. 85 8 SOOT BLOWING SEQUENCES ........................................................................85 8.1 Long Soot Blower Sequence ...............................................................................87 8.2 Rotary Soot Blower Sequence.............................................................................87 8.3 Boiler & Economizer Soot Blower Sequence .....................................................88 8.4 Economizer Soot Blower Sequence ....................................................................90 9 ATTACHMENTS ..................................................................................................93
1001854 / 0D / Page 4 of 93
1 GENERAL ITEMS
1.1 Definitions/Abbreviations
Local control Remote control Manual control Automatic control Operation of the equipment is outside the IAS system (Switchboard or local panels). Operation of the equipment is performed from the IAS system. Operation of the equipment is performed manually by the operator from the IAS operator stations or BGB. Operation of the equipment is performed by IAS control logic (remote mode only).
ABC AVR BGB BNP CCR CTR DG DP E/R ECR EOP EOT ESD F&G FDF FDS FO FS
Automatic Boiler Control Automatic Voltage Regulation Boiler Gauge Board Burner Operation Panel Cargo Control Room Custody Transfer System Diesel generator Differential Pressure Engine room Engine Control Room Emergency Operator Panel Engine Order Telegraph Emergency Shutdown Fire and Gas Forced Draft Fan Functional Design Specification Fuel oil Field Station (Cabinet with controller and/or RIO modules)
1001854 / 0D / Page 5 of 93
FV FW GMS HD HS HT HV I/O IAS IGC code IGV KM LD LNG LO LR LT LV MCC MCR MHI MLP MV MT NDU OS PMS PV RCS RCU
Forcing Vaporizer Fresh water Gas Management System High Duty Compressor Hand Switch High Temperature High voltage (6.6 kV systems) Input / output Integrated Automation System International Code for the Construction and Equipment of Ships carrying Liquefied Gases in Bulk. Inlet Guide Vane Kongsberg Maritime Low Duty Compressor Liquefied Natural Gas Lubrication oil Lloyds Register Low temperature Low Voltage (440V / 220 V systems) Motor Control Center Maximum Continuous Rate Mitsubishi Heavy Industries Manual Loader Panel Main Vaporizer Main Turbine Net Distribution Unit Operator Station Power Management System Process Variable Remote Control System Remote Controller Unit
1001854 / 0D / Page 6 of 93
RIO SBRP SP SVC SW TG VDU
Remote Input Output Unit Soot Blower Relay Panel Set Point Simrad Vessel Control Sea water Turbine Generator Video Display Unit
1001854 / 0D / Page 7 of 93
1.2 Flowchart symbols

Symbols
Condition for next step Accomplished OR Failed (Timout) Accomplished Action Failed (Timout)
Description
This symbol represents any kind of processing function.
This symbol represents a decision or switching type function
This symbol represents a named process, such as a subroutine.
This symbol represents data input by manual means
This symbol represents a process performed by operator or automatically by process event.
Indicates a crossreference within the same page of the flow chart.
This symbol represents the end of a program flow.
This symbol represents a data that is displayed for human use.
This symbol represents a delay/timer
1001854 / 0D / Page 8 of 93
2 RESPONSIBILITIES
Kongsberg Maritime is responsible for this document.
3 BOILER GENERAL
3.1 General
Two main boilers are installed, both with the following specifications: Maker: Type: Steam pressure: Steam temperature: Evaporation: Feed water temperature at ECO outlet: Efficiency Fuel Oil: Boiler design pressure: Auxiliary de super heater outlet: Steam quantity: Temperature: Max: 40,000 kg/h Max: 350 C , normal: 288.5 C. Mitsubishi Heavy Industries. MB-4E-NS2. 60.3 bar. 515 C. Normal: 50,000 kg/h , max: 61,500 kg/h 139,8 C. 88,5 % 76,5 bar
1001854 / 0D / Page 9 of 93
Figure showing general arrangement:

IAS Ethernet HUB A
IAS Ethernet HUB B
MB1 Control Cabinet
MB2 Control Cabinet
Boiler Common / Soot blowers Cabinet

RCU RCU
RCU
RCU
RCU
RCU
HUB
HUB
HUB
HUB
HUB
HUB
RIO
Analogue control sensors
RIO
Analogue control sensors
RIO
Common AI/AO
RIO
Flame scanner #1 MT Trip/Pwr Reduction
RIO
Flame scanner #1 MT Trip/Pwr Reduction
RIO
Common DI/DO
RIO
Flame scanner #2
RIO
Flame scanner #2
RIO
Common DI/DO
RIO
Analogue Control Sensors Analogue Control Vlv's
RIO
RIO
RIO
Manual Loader
RIO
Manual Loader
RIO
Manual Loader
RIO
Manual Loader Operator Panel
RIO
Manual Loader Operator Panel
RIO
Div control
RIO
Common Vlv's Operator Panel Others
RIO
Common Vlv's Operator Panel Others RIO
Soot Blower Control
RIO
Common Vlv's Operator Panel
RIO
Common Vlv's Operator Panel RIO Soot Blower Control
RIO
Operator Panel
RIO
Operator Panel RIO Soot Blower Control
RIO
No1 Burner Control
RIO
No1 Burner Control RIO Soot Blower Control
SBP
RIO No2 Burner Control RIO No2 Burner Control
RIO
No3 Burner Control
RIO
No3 Burner Control
BGB
1001854 / 0D / Page 10 of 93
BGB, Boiler Gauge Board The local board including graphic operator panel, manual loader functions, emergency operator function, some instruments. panels including BNP, MLP & EOP. BGB is MHI supply. Graphic Operation Panel This panel is located at the BGB. It contains lamps and switches for local boiler control also manual loader functions are included. Graphic Operator panel is MHI supply.
EOP, Emergency Operation Panel This panel is located locally at the BGB. From this panel FO burners can be started/stopped in case of emergency. EOP is MHI supply.
Soot Blower Relay Panel This cabinet is delivered by MHI. The cabinet controls soot blowing sequences of the two boilers. ABC RIO units are installed here for soot blower control. ABC Cabinets ABC cabinets consists of three cabinets . FS-11, Main boiler no1 control FS-13, Main boiler no2 control FS-12, Boiler common & soot blower control
1001854 / 0D / Page 11 of 93
Boiler main functions: Start / stop of oil burners Start / stop of gas burners Nitrogen purge of gas lines Fuel mode changeover Burner automatic increase/decrease according to boiler load Automatic FO backup Automatic FO boost up in case of gas supply failure Drum water level control Steam temperature control Atomizing steam pressure control Purge steam pressure control FO pump pressure control Steam pressure control, including: - Boiler master control with load ratio control - Air flow control including O2 control - FO flow control - GAS flow control Steam dump control Local panels with operation. Boiler safety. Emergency operation.
1001854 / 0D / Page 12 of 93
3.2 Burner Management

Burner sequence control and boiler control loops are integrated in the ABC process stations. Data exchange between the process stations is done via the dual Ethernet. All commands and parameters are available from IAS/ABC operator stations. In addition commands and control can be made from the Boiler Gauge Board, via local/remote switches. Emergency operation of burner can be done from the EOP, which is totally independent from IAS. When emergency operation is selected, both ABC and BMS are changed to emergency mode. Boiler shutdown system is mostly within the IAS boiler control system. Some shutdowns are hardwired (by MHI).
3.3 CPU Redundancy

Each of the ABC process stations are equipped with a redundant CPU. Normally the main CPU runs and activates the process outputs. The slave CPU is running in parallel with the main CPU but process output are disabled (hot backup). In case of main CPU fails, the process outputs to the AO/DO cards are controlled by the slave CPU.
1001854 / 0D / Page 13 of 93
3.4 Power Distribution

Each of ABC cabinets are supplied with redundant power system. See figure below, indicating the power supply principle. Each of the UPS & AC/DC converters contains sufficient capacity to supply the system.
Process Station Cabinet Main Supply Emerg Supply

220V AC UPS 1 24V DC 220V AC UPS 2 24V DC RCU B RCU A
RIO Units
BGB 220V AC 24V DC RIO Units 220V AC 24V DC
SBRP
RIO Units
1001854 / 0D / Page 14 of 93
4 BURNER SEQUENCES
General. Starting / stopping of burners are made by a sequencer system within the IAS. This is applicable for either IAS control or BGB local control. A selector switch at the BGB decides which control place to be active. In case of any trouble during sequence execution a sequence jam status is issued. In case of sequence jam the running sequence will perform a clean up (error treatment). All sequences except stop sequences will be blocked until operator resets the sequence jam (reset button at IAS monitor, acknowledge button at BGB). Burner Start. FO / GAS start buttons are prepared separately which means operator freely can decide each burner firing mode. Burner asynchronous firing is allowed in manual mode. Burner Stop. FO / GAS stop buttons are prepared separately. NOTE: 1 burner firing at gas only is not recommended for safety reasons. Burner Auto mode. In order to select auto mode the burners must be firing in synchronous mode. Burner manual sequences is then inhibited. The following sequences are then available: Burner automatic increase, starts automatically. Burner automatic decrease, starts automatically. Mode change FO => Dual, need operator intervention to start. Mode change Dual => GAS, need operator intervention to start. Mode change GAS => Dual, need operator intervention to start. Mode change Dual => FO, need operator intervention to start. FO auto backup (GAS => Dual), starts automatically FO boost up (GAS => FO), starts automatically.
1001854 / 0D / Page 15 of 93
4.1 Fuel Oil Burning

Starting fuel oil burners: The individual fuel oil burners can be started and stopped either from the operator station (IAS control) or from the BGB (local control). If all flames are off and operation position is BGB then first burner starting must be done from BGB. Operation position transfer BGB => IAS is blocked during boiler stopped condition. If all flames are off and operation position is IAS then first burner starting can be done from IAS. In addition burners can be started and stopped from EOP (not described here since this is an independent system). Start FO burner 1 (by activating the start FO 1 pushbutton). Start FO burner 2 (by activating the start FO 2 pushbutton). Start FO burner 3 (by activating the start FO 3 pushbutton).
1001854 / 0D / Page 16 of 93
Operator Preparations: Reset of all FO trip conditions. Reset of all boiler trip conditions. Start of FO supply pump. Start of FDF Open FO shutoff valve.
Sequence Description: At the time all interlocks are lifted the start FO sequence can be started. The starting will be carried out by a sequence controller according to following description. First the corresponding burner atomizing steam valve is opened. Furnace purge will then be carried out by opening of all burner air slide dampers and FDF vane is set to purge position. Furnace purge will be continued for 90 seconds (confirmed by air volume). When the furnace purge is completed the not starting burner air registers will closed and FDF vane will be set to start position. Fuel oil control valve will be set to start position. The igniter will be inserted and the spark activated. When igniter spark and position is confirmed the burner FO valve will be opened. Furnace purge sequence uses air flow signal from differential press transmitter (247B) for detection of sufficient air volume. Differential press transmitter for air flow detects press between wind box and furnace. And air flow is calculated based on measured press.
1001854 / 0D / Page 17 of 93
Flowchart for starting fuel oil burners, the first FO burner:

Note : Only One Burner Can Be Started At The Time Condition for next step - Atm Steam Vlv Opened & - Steam Purg Vlv Closed Action Open Bnr Atm Steam Valve & Close Steam Purge Valve Timeout : 10 sec Error SEQ-1 Start Oil Burner (Initial FO Burner) Start Start Permissive Terminate - Burner On from BGB(local) if all Bnr off - Burner On from Monitor(IAS) if all Bnr off and OR IAS Mode established
- Boiler Purged Status Set
Start Furnace Purge Sequence (SEQ-2) Timeout : 6 min
Error
- Fd Fan Vane In Start Pos(2-6%)
Force Fd Fan Vane To Start Pos. (5%) Timeout : 10 sec Close Bnr Register which are not set for start Timeout : 10 sec
Error
- Boiler FO Shutoff Valve Opened - All Bnr Fo Valves Closed - Not Fo Trip - All Burner Register Closed & - Not F/E Abnormal - All Bnr GAS Shutoff Valves Closed - If ignitor is bypassed then portable ignitor must be inserted(Limit Switch) - Not boiler trip - Stop Seq Not active - FDF Run - Not Seq Jam
- Selected Bnr Register Opened & - Not Selected Registers Closed
Error - Boiler FO Shutoff Vlv Close Cmd - Boiler Trip - FO Trip Error OR
- FO Recirc Valve Closed
Close FO Recirc Valve Timeout : 10 sec
- FO Ctr Vlv In Start Pos(15-21%)
Set FO Ctrl Vlv To Start Pos(18%) Timeout : 20 sec
Error
- Air Rate Normal (8000-4000kg/h) & - FO Press Ok(>10bar) & - FO Temp Ok or Temp byps On OR Waiting timer 10s
Check Air Rate & FO Press & FO Temp Timeout : 60 sec
Error
- All Flames OFF Waiting Timer: 1s
Check All Flames are OFF Timeout : 5 sec
Error
- FO Valve opened & - Igniter inserted - Igniter In Down Position & Spark On & Portable Igniter Not Selected OR - Igniter In Down Position & Portable Igniter Selected & Spark On Waiting Timer: 2s - Burner Fo Valve 1 Opened & - Burner Fo Valve 2 Opened & - Flame Detected Direct Error if: - Falme Fail Waiting Timer: 5s
Open FO Valve 223B & Insert Igniter Timeout : 20 sec Activate Retractable Igniter if Not Portable igniter Selected Or Activate Portable Igniter if Selected Timeout : 10 sec
Error
Error - Set Alarm - Close Burner Fo Valve's
Open Burner Fo Valve 225B Timeout : 10 sec Error (Flame fail is activated 7s afterFO vlv open cmd)
- Deactivate & Retract Igniter - Close Burner Register If Gas Burner Is Not Active - Close Atomize Steam Valves
- Igniter Deactivated & - Igniter Retracted Waiting timer 7s
Deactivate & Retract Igniter Timeout : 10 sec
Error
- Open Stm Purge Vlv if Any Bnr is ON - Release FDF Vane
- Fd Fan Vane Released & - FO Control Valve Released Note: FO Valve 223B is Slow Acting Downstream side FO Valve 225B is Fast Acting
Release Fd Fan Vane & FO Control Valve Timeout : 5 sec
Error
- Release FO Ctr Vlv - Open FO Recirc Valve
End
1001854 / 0D / Page 18 of 93
Flowchart for furnace purging:
SEQ-2 Furnace Purging Condition for next step - Burner 1 Register Opened & - Burner 2 Register Opened & - Burner 3 Register Opened Action Open All Burner Registers Timeout : 15 sec
Start Start Permissive Terminate
- Start from Burner Start seq. or - Manual Purge from BGB in Local mode or - Manual Purge from IAS in IAS mode
Error - All Bnr FO Vlv's Closed & - FDF Run
- FDF in Furn Prg Pos +/- 3% & - Air Flow > 40.000 Kg/h
Force Fd Fan Vane Fully Open Timeout : 30 sec
Error
- Air volume > 900 m3 & - Minimum Timer 60 sec
Purging (min 60s) Timeout : 300 sec
Error
- FDF Stopped - Boiler Manual Trip
Purge Status > 1min Or FDF Not RunOr Any FO Vlv Open Command Or FO Shut Valve Open & Any Bnr On
Set Reset
Set Boiler Purged Status (No Set if Man Purge)
Furnace Purge Seq Failed - Release FD Fan Vane - Close All Burner Registers
End
Manual Purge. At the BGB there is a switch for purge request. This switch will activate the above mentioned sequence if boiler is stopped.
1001854 / 0D / Page 19 of 93
Starting fuel oil burners, when another burner is on: In manual mode operator is responsible for checking FO pressure and boiler master demand by him self. Auto mode is described in the chapter for burner automatic increase / decrease. The individual fuel oil burners can be started and stopped either from the operator station (IAS control) or from the BGB (local control). Start FO burner 1 (by activating the start FO 1 pushbutton). Start FO burner 2 (by activating the start FO 2 pushbutton). Start FO burner 3 (by activating the start FO 3 pushbutton).
Sequence Description: The sequence starts by open the burner atomizing steam valve and closing of steam purge valve. Then igniter is lowered and simultaneously burner FO valves (up stream 225B & down stream 223B) are opened. The burner flame should be detected within 7 seconds after FO valves are opened if not burner will trip.
1001854 / 0D / Page 20 of 93
Flowchart for starting fuel oil burners, when another FO burner is on:
Note : Only One Burner Can Be Started At The Time Condition for next step - Atm Steam Vlv Opened & - Steam Purge Vlv Closed & Action Open Atm Steam Vlv & Close Steam Purge Vlv Timeout : 10 sec Error SEQ-3 Start Oil Burner (Next FO Burner) Start Start Permissive Terminate - Burner On from BGB(local) if any flame on - Burner On from Monitor(IAS) if any fl on OR - Start Request from Bnr auto inc (SEQ-9 step 2 , SEQ-9 step 5)
- FO Press OK OR - FO Mode OR - BMS Manual Mode
Adjust FO Press if Auto & Dual Timeout : 10 sec
Error
- Any Burner Is Active - Burner FO Valves Closed & - Burner Register Closed if Gas Burner is Off - Not Seq Jam - FO Press > 10 bar if Auto Mode
- FO Recirc Valve Closed
Close FO Recirc Vlv Timeout : 10 sec
Error - FO Shutoff Vlv Close Cmd - Burner Fo Piston Valve Shutdown - Boiler Trip - FO Trip OR Note : If all burner flame on signals are llost before before a flame is detected on the burner being ignited the start sequence will be terminated.
- FO Control Vlv in Start Pos OR - Any FO Bnr On
Set FO Control Vlv to Start Pos if No FO Bnr On Timeout : 10 sec
Error
- Igniter In Down Position & Spark On & Portable Igniter Not Selected OR - Igniter In Down Position & Portable Igniter Selected & Spark On Or - Corresponding Gas Bnr On
Insert and activate Retractable Igniterif Not Portable igniter Selected Or Activate Portable Igniter if Selected If Corresponding GAS Bnr is Off Timeout : 30 sec
Error
- Burner FO V(223B) Open Cmd & - Burner FO V(225B) Open Cmd
Open Bnr FO Vlv (223B) & Open Bnr FO Vlv (225B) Timeout : 10 sec (Flame fail is activated 7s afterFO vlv open cmd)
Error
FO Burner Ignition Seq Failed
-Flame Detected Waiting timer 5s
Open Burner Register after 2 s Timeout : 10 sec
Error
Close Burner FO Valves Deactivate & Retract Igniter
- Ignitor Deactivated & - Ignitor Retracted Waiting timer 7s
Deactivate & Retract Ignitor Timeout : 20 sec
Close Burner Register If Gas Burner Is Not Active Error Close Atomize Steam Valve Open Steam Purge Valve
End
1001854 / 0D / Page 21 of 93
Stopping fuel oil burners: The individual fuel oil burners can be stopped either from the operator station (IAS control) or from BGB (local control). Stop FO burner 1 (by activating the stop FO 1 pushbutton). Stop FO burner 2 (by activating the stop FO 2 pushbutton). Stop FO burner 3 (by activating the stop FO 3 pushbutton). The stop of burners is always available and will terminate any start attempt. The following commands are executed: Closing individual fuel oil piston valves. De-energizing igniter (if energized). Retracting Igniter (if inserted). Closing burner register if gas burner is not active (individual gas valve closed). Steam purging of burner, atomizing steam valve will close (if no other burner is active). In case of stopping last burner a furnace purge will be carried out.
1001854 / 0D / Page 22 of 93
Flowchart for stopping fuel oil burners:

SEQ-4 Stop FO Burner Condition for next step - Burner Fo Piston Valve 1 Closed & - Burner Fo Piston Valve 2 Closed Action Close Burner FO Valves Timeout : 10 sec Error - FO Burner On Last Bnr & not gas firing (All Bnr FO & GAS Vlv's Closed) Yes - Bnr Atm Stm Vlv Closed & - FO Recirc Vlv Opened & - All Stm Purge Vlv Closed Close Bnr Atm Stm Vlv Open FO Recirc Vlv Close All Stm Purge Vlv's Timeout : 20 sec Error Start Start Permissive - Burner Off from BGB(in Local) - Burner Off from Monitor (in Remote) - Stop Request from Bnr auto dec Seq (SEQ-10 step 2 or SEQ-10 step 4). - Bnr Flame Fail(FO or Dual) OR
No
- Burner 1 Register Opened & - Burner 2 Register Opened & - Burner 3 Register Opened
Open All Register Timeout : 20 sec
Error
- FDF in Purge psition (>80%) & - Air Flow > 40.000 Kg/h
Set FDF to Purge Position 80% Timeout : 30 sec
Error
Timer 30 seconds
- FDF Released
Release FDF Timeout : 20 sec
Error
- Burner 1 Register Closed & - Burner 2 Register Closed & - Burner 3 Register Closed
Close All Register Timeout : 20 sec
Error
A Open Stm Purge Vlv & Open FO Recirc V if Last FO Bnr Timeout : 30 Sec
- Stm Purge Vlv Opened & - Any FO Bnr On Or FO Recirc V Closed
Error
FO Burner Extinguish Seq Failed - Close Burner FO Valves - Deactivate & Retract Igniter - Close Air Register if Gas Burner is Not Active
Timer 5 sec
-Bnr Register Closed OR - Gas firing is on
Close Bnr Register if Gas firing is off Timeout : 20 sec
Error
- Close Atomize Steam Valve - Open Steam Purge Valve if Any Burner On
Timer 30 sec - Release FDF Vane -Bnr Atm Stm Vlv Closed Close Bnr Atm Stm Vlv Timeout : 20 sec - Open FO Re-circ Valve if All FO Burners are Off
Error
End
1001854 / 0D / Page 23 of 93
4.2 Gas burning

Start up of gas burning can be done either by manually starting each burner or by using the automatic sequence. Operator Preparations: The operator must prepare the following conditions before GAS firing can start: FO firing must be established. Reset of all GAS trip conditions. Open Master GAS valve. Open boiler GAS valve.
Manual Mode The individual fuel gas burners can be started and stopped from the IAS operator station or from BGB in local control. Start GAS burner 1 (by activating the GAS 1 ON pushbutton). Start GAS burner 2 (by activating the GAS 2 ON pushbutton). Start GAS burner 3 (by activating the GAS 3 ON pushbutton). Stop GAS burner 1 (by activating the GAS 1 OFF pushbutton). Stop GAS burner 2 (by activating the GAS 2 OFF pushbutton). Stop GAS burner 3 (by activating the GAS 3 OFF pushbutton)
Auto Mode: The operator may select FO/Dual/ GAS mode from the IAS operator stations. The transfer between modes is then made by a sequence program. Number of burners is decided by boiler load.
1001854 / 0D / Page 24 of 93
Sequence Description: Gas burners can be started once the corresponding FO burner is in operation. In addition the master gas valve and boiler GAS valve must be opened, the burner GAS valves must be closed. The vent valves are controlled automatically by the sequences or by GAS valves positions. During GAS burner ON/OFF operations the N2 purging of lines/burners will be performed automatically when needed. At the end of gas firing the operator must manually close boiler GAS valve and master GAS valve. Flowchart for starting fuel gas burners:
Note : Only One Burner Can Be Started At The Time Condition for next step - Gas Ctrl Valve In Start Position Or - Any Other Gas Burner Is Active
SEQ-5 Start Gas Burner Action Check Gas Ctrl Vlv To Start Pos. If No Other Gas Burner Is Active Timeout : 10 sec
- Gas Burner On from BGB (Local Mode) - Gas Burner On from Monitor(IAS) OR - Start Req from Bnr auto inc/dec seq. (SEQ-9 step3, SEQ-9 step6)
Error
- Waiting Timer 3 sec
Set Air Bias Timeout : 10 sec
- Burner Gas Valve 1 Opened & - Burner Gas Valve 2 Opened &
Open Burner Gas Valves Timeout : 10 sec
Error
Master Gas Valve Open Boiler Gas shutoff valve Opened Burner Gas Valve1 Closed Burner Gas Valve2 Closed Not Boiler Trip Not FO Trip Not Gas Trip Master N2 Purge Sequence Not Active Header N2 Purge Sequence Not Active Header N2 Purge Valve Closed Burner N2 Purge Valve Closed Not Seq Jam Corresponding FO Bnr On
&
- Master Gas Valve Closed - Gas Trip Note : If Corresponding Oil Burner "Flame On" Signal Is Lost Before Gas Flame Is Detected, The Start Sequence Will Be Terminated. OR
Release Gas Control Valve
GAS Burner Ignition Seq Failed - Close Burner Gas Valves
Reset Air Bias
- Reset Air Bias Adjustment
End
1001854 / 0D / Page 25 of 93
Flowchart for stopping fuel gas burners:

- Stop from BGB (Local Mode) - Stop from Monitor(IAS) - Stop request from burner inc/dec OR (SEQ-10 step2, SEQ-10 step4) - Stop request from Dual=>FO seq - Bnr Falme Fail - Burner Gas Valve's Not Close Cmd
SEQ-6 Stop Gas Burner Condition for next step - Burner Gas Valve 1 Closed & - Burner Gas Valve 2 Closed Action Close Burner Gas Valves Timeout : 10 sec
Start Start Permissive
Error
- Air Bias Adjustment is Reset
Reset Air Bias Adjustment Timeout : 10 sec
Error
- Any Burner Is Active Or - Furn Purge Run Waiting Timer 10 sec
Furn Purge Req If Last Bnr Timeout : 10 sec
Error
- Burner N2 Purge V Opened Or - Furn Purge Seq Run
Start Burner N2 Purge If Any Bnr Firing Timeout : 10 sec
Error
Gas Burner Extinguish Seq Failed - Bnr register Closed Or - FO Bnr On Or - Furn Purge in Progerss Close Bnr Register If FO Bnr is Off & Not Furn Purge Timeout : 10 sec Error - Close Burner Gas Valves - Close Air Register if FO Burner is Not Active - Close Burner N2 Purge Valve
End
1001854 / 0D / Page 26 of 93
Flowchart for Boiler Gas Valve Open:

SEQ-7 Blr Gas Valve Open Condition for next step - Blr Gas Vlv Opened Action Open Blr Gas Valve. Timeout : 10 sec Error - Master Gas Valve Open - All Bnr Gas Vlv's Closed - All Bnr N2 Purge Vlv's Closed - Not Boiler Trip - Not FO Trip - Not Gas Trip - Hdr N2 Purge Seq Not Active Error Start Start Permissive Terminate - Open from Monitor(IAS) OR
Timer 5 sec
&
- Hdr N2 Vent Vlv Closed
Close Hdr N2 Vent Vlv Timeout: 10 sec
- Gas Control Vlv in Ign Pos
Set Gas Control Vlv to Ignition Pos. Timeout : 10 sec
Error
- Master Gas Valve Closed - Gas Trip OR
Boiler Gas Valve Open Seq Failed - Close Boiler Gas Valve - Open Header Vent Valve - Release Gas Control Vlv End
1001854 / 0D / Page 27 of 93
Flowchart for Boiler Gas Valve Close:

SEQ-8 Blr Gas Valve Close Condition for next step - Blr Gas Vlv Closed Action Close Blr Gas Vlv Timeout: 10 sec Error Start Start Permissive - Close from Monitor(IAS) - Close if Gas Trip OR
- Blr Gas Vlv Not Closed
- Gas Ctr Vlv Fully Closed(<1%)
Set Gas Ctr Vlv Fully Closed Timeout: 10 sec
Error
No
FO Burning On ?
Yes - Hrd/Bnr N2 Purge to Furn Seq Run If FO Burning: Start Hrd/Bnr N2 Purge to Furn (SEQ-19) Timeout : 10 sec A Error
Yes - Hdr N2 Purge to Vent Run Start Hdr N2 Purge to Vent (SEQ-17) Timeout : 10 sec
Error
Boiler Gas Valve Close Seq Failed - Close Boiler Gas Valve - Close Hdr N2 Purge Valve - Open Header Vent Valve - Close All Burner Gas Valves - Release FDF A End
1001854 / 0D / Page 28 of 93
4.3 Burner Auto Mode

Burner auto mode can be selected when the burning burners are burning in the same fuel mode e.g. FO, Dual or FG. Base burner is required in order to establish auto mode. In case of burner manual mode, any burner can be operated. For example, one gas burner firing can be made at gas only mode. Burner automatic increase / decrease, fuel mode changeover sequence is cancelled during burner manual mode. When operator selects burner manual mode, operator must also take care of suitable burner number to be matched with boiler load and general boiler safety.
FO Mode Bnr1 FO Burning Bnr2 FO Burning Bnr3 FO Burning &
&
OR
Bnr1 GAS Bnr2 GAS Burning Bnr3 GAS Burning Burning Dual Mode Bnr1 FO Burning Bnr1 GAS Burning
&
OR
& &
OR
Bnr2 FO Burning Bnr2 GAS Burning
& &
OR OR
OR & Auto Mode Possible
& Bnr3 FO Burning Bnr3 GAS Burning &
GAS Mode Bnr1 GAS Bnr2 GAS Burning Bnr3 GAS Burning Burning
&
OR
&
Bnr1 FO Burning Bnr2 FO Burning Bnr3 FO Burning FO Trip Ctr Pos IAS FO Shut V Open Bnr1 Flame Fail Bnr2 Flame Fail Bnr3 Flame Fail
&
OR
OR &
Bnr1 FO or Gas Burning Bnr1 Gas Burning Bnr2 Gas Burning Bnr3 Gas Burning
OR
&
&
FO Trip
1001854 / 0D / Page 29 of 93
4.4 Burner Automatic Increase/Decrease

Burner Increase: When burner auto mode is selected, the number of burners is controlled automatically according to the boiler demand. This mode is not applicable in gas only firing of one gas burner. The system will monitor the boiler demand e.g. output from master pressure controller and the FO pressure or total fuel calorie. Also during manoeuvring a minimum numbers of burners are considered. The priority for starting is predefined as follows: No.1 burner => No.2 burner => No.3 burner. The priority for stopping is predefined as follows: No.3 burner => No.2 burner => No.1 burner. Burner Increase: Request for next burner will be calculated as follows:
Mode
No Of Bnr 1 bar 2 bnr 1 bnr
Limit Boiler demand > 13,5 Gcal/h & FO pressure > 13 bar Boiler demand > 27,0 Gcal/h & FO pressure > 12 bar Boiler demand > 14,0 Gcal/h & total fuel calorie > 14,0 Gcal/h & FO press > 12 bar Boiler demand > 28,5 Gcal/h & total fuel calorie > 28,5 Gcal/h & FO press > 10 bar Boiler demand > 25,0 Gcal/h & GAS Press > 0,1 bar
Result 1 => 2 bnr 2 => 3 bnr 1 => 2 bnr 2 => 3 bnr GAS=>Dual
FO
Dual
2 bnr 2 bnr
GAS
Note: In case of burner increase in GAS mode, the GAS => Dual sequence will be activated. Then dual burner will increase if required. 12,4 Gcal/hr is equivalent to 1200kg/hr of fuel oil, 20,6 Gcal/h is equivalent to 2000 kg/h.
1001854 / 0D / Page 30 of 93
Burner Decrease: Request for stopping burner will be calculated as follows: Mode No Of Bnr 3 bnr FO 2 bnr 3 bnr Dual 2 bnr 3 bnr GAS 2 bnr Limit Boiler demand < 16,0 Gcal/h & FO pressure < 5,5 bar Boiler demand < 8,0 Gcal/h & FO pressure < 5,0 bar & M/T stop for 15 min. Boiler demand < 16,0 Gcal/h & total fuel calorie < 18,0 Gcal/h Boiler demand < 9,0 Gcal/h & total fuel calorie < 10,2 Gcal/h & M/T stop for 15 min. Boiler demand < 17 Gcal/h & GAS hdr pressure < 0,12 bar Boiler demand < 6,0 Gcal/h & GAS hdr pressure < 0,1 bar Result 3 => 2 bnr 2 => 1 bnr 3 => 2 bnr 2 => 1 bnr 3 => 2 bnr GAS=>Dual
Main Turbine Interaction: In case of main turbine trip the numbers of burners are limited to maximum 2 burner.
TimerOff
MT Vlv Lift > 50% MT Telegraph Stop
30s
& OR MT Telegraph Astern MT Vlv Lift Astern Full &
Crash Astern, Crash Stop (Burner No3 Auto Decrease) (By SEQ-10)
TimerOff
MT Vlv Lift Astern Full
30s
& OR MT Telegraph Stop MT Telegraph Astern MT Vlv Lift > 50% &
Crash Ahead, Crash Stop (Burner No3 Auto Decrease) (By SEQ-10)
1001854 / 0D / Page 31 of 93
Flowchart for Burner Automatic Increase:
SEQ-9 Burner Increase
- FO Mode: Boiler Demand & FO Prs - Dual Mode: Boiler Demand & Tot Calorie Input - GAS Mode: Boiler Demand & GAS Press - No of burners are 1 or more - Not MT Interlock by Crash Astern/Ahead/MT Trip - Auto mode selected - Bnr decrease Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - GAS => Dual Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Seq Jam - Not Burner Abnormal
OR
&
Condition for next step - Burner 2 is OFF - Burner 2 Ready*1)
Action Check Burner 2 is OFF: Timeout : 1sec 1 No
OR Start FO Burner 2 (SEQ-3) if FO or Dual mode Timeout : 60sec 2
- FO Burner 2 is ON & - Ignition Seq Compleate
Error
Stop FO Burner 2 (SEQ-4) 7
- FO Mode, OR - Burner2 is Dual Firing
Start GAS Burner 2 if: Dual Mode & GAS Bnr2 is OFF (SEQ-4) Timeout : 60sec
Error 3
Stop GAS Burner 2 (SEQ-6) 8
Condition for next step - Burner 3 is OFF - Burner 3 Ready
Action Check Burner 3 is OFF: Timeout : 1sec 4 No
- FO Burner 3 is ON - Ignition Seq Compleate
Start FO Burner 3 (SEQ-3) if FO or Dual Mode GAS>Dual seq (SEQ-13) if GAS mode 5 Timeout : 60sec Start GAS Burner 3 if: Dual Mode & GAS Bnr3 is OFF (SEQ-4) Timeout : 60sec
Error
Stop FO Burner 3 (SEQ-4) 9
- FO Mode, OR - Burner 3 is Dual Firing OR GAS mode
Error 6
Stop GAS Burner3 (SEQ-6) 10
Alarm: Burner Increase Failed
End
*1) Ready:
FO Mode; FO Burner Start Permissive OK Dual Mode; FO Burner & Gas Burner Start Permissive OK
1001854 / 0D / Page 32 of 93
Flowchart for Burner Automatic Decrease:

SEQ-10 Burner Decrease Start Start Permissive Terminate -FO Mode: Boiler Demand & FO Prs - Dual Mode: Boiler Dem & Tot Calorie OR - GAS Mode:Boiler Demand & GAS Prs - MT Chrash Ast/Ahd if 3 Bnr Firing - MT Trip & 2bnrs or More Firing - Number of burners are 2 or more - Telegraph Stop + 15min - Auto Mode Selected - Bnr increase Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - GAS => Dual Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Burner Abnrmal - Not Seq Jam
Condition for next step - Burner 3 is ON
Action Check Burner 3 is ON: Timeout : 1sec 1 No
&
- FO Burner 3 is OFF & - GAS Burner 3 is OFF
Stop FO Burner 3 if: FO or Dual Mode (By SEQ-4) & Stop GAS Burner 3 if: Dual or GAS mode (By SEQ-6) Timeout : 60sec
Error
Condition for next step - Burner 2 is ON
Action Check Burner 2 is ON: Timeout : 1sec 3 No
- FO Burner 2 is OFF& - GAS Burner 2 is OFF
Stop FO Burner 2 if: FO or Dual Mode (By SEQ-4) & Stop GAS Burner 2 if: Dual mode (By SEQ-6) & GAS=>Dual (SEQ-13) if GAS mode Timeout : 60sec
Error
Alarm: Burner Dec. Failed 5 End
1001854 / 0D / Page 33 of 93
4.5 Fuel Mode Changeover

There are three different modes of fuel selection. Fuel Oil Only: Dual Fuel: Fuel Gas Only: Only oil burners ON. Both gas and oil burners ON Only gas burners ON
Available sequence for change-over is: Fuel oil => <= Dual fuel => <= Fuel Gas. Special Mode: Low Load Gas Mode Low Load Gas mode can be selected either in dual mode condition or in gas mode condition. This mode enables gas only firing during main turbine in maneuvering zone.
FO => Dual Fuel: If activated the system will start up gas burners where oil burner is already on.
1001854 / 0D / Page 34 of 93
Flowchart for Changeover FO => Dual:

SEQ-11 Mode: FO => Dual Start Start Permissive Terminate - IAS mode: OR Dual button from Monitor is pressed.
Condition for next step - GAS Control Vlv in Start Pos
Action Set GAS Control valve to start position Timeout : 1sec 1 No All Bnr's GAS vlv's closed Master GAS valve open Boiler GAS vlv open Burner mode = Auto Bnr Increase Seq Off Bnr Decrease Seq Off Dual => GAS Seq Off GAS => Dual Seq Off Dual => FO Seq Off FO Boost Up Seq Off Not Burner Abnormal Not Seq Jam
&
- Air Flow Controller Add Air Set
Set Add Air to Air Flow Controller Timeout : 1sec
Error 2
- (Bnr1 GAS Bnr is ON & - (Bnr2 GAS Bnr is ON or Bnr2 FO Bnr is OFF) & - (Bnr3 GAS Bnr is ON or Bnr3 FO Bnr is OFF) Wating Timer 20 sec
Open Bnr1 GAS Valves (1&2) Open Bnr2 GAS Valves (1&2) if FO Bnr On Error Open Bnr3 GAS Valves (1&2) if FO Bnr On Timeout : 60sec 3 -Boiler Trip - FO Trip - GAS Trip
OR
Reset Add Air to Air Flow Controller Timeout : 1sec 4
Reset FG Control Vlv Start Position Timeout : 1sec 5
FO => Dual Seq Failed
- Stop GAS Burner 1 (SEQ-6) - Stop GAS Burner 2 (SEQ-6) - Stop GAS Burner 3 (SEQ-6) - Reset Add Air to Air Flow Controller - Reset GAS Control Vlv Start Position 6 End
1001854 / 0D / Page 35 of 93
Dual => GAS: When mode switch is changed from dual to GAS, the system will stop oil firing.
SEQ-12 Mode: Dual => GAS Start Start Permissive Terminate - IAS mode: OR GAS button from Monitor is pressed.
Condition for next step
Action Set FO Burner Extinguish Request to FO Flow Controller Timeout: 120sec
- FO Press < 3 bar
Error
- FO Burner 1 is OFF - FO Burner 2 is OFF - FO Burner 3 is OFF
- Stop FO Bnr1 (SEQ-4) - Stop FO Bnr2 (SEQ-4) - Stop FO Bnr3 (SEQ-4) if Dual Bnr ON Timeout: 60sec
Error
- Master GAS valve open - Number of Dual bnr's are 2 or more - Boiler GAS vlv open - Bnr mode = Auto - Bnr Increase Seq Off - Bnr Decrease Seq Off & - FO => Dual Seq Off - GAS => Dual Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Bnr Abnormal - Not Seq Jam - GAS Press > 0.1 bar - LD Comp 1 or 2 Running - Not FO Auto Backup Order Active - Boiler trip - FO Trip - GAS Trip - Auto Backup Order - FO Boost Up Order OR
Reset FO Burner Extinguish Request to FO Flow Controller
Dual => Gas Sequence Failed
End
1001854 / 0D / Page 36 of 93
GAS => Dual Fuel: When mode switch is changed from GAS to dual, the system will start up oil burners where gas burners are firing. Some process conditions will start GAS => dual sequence automatically by means of FO auto backup order. In case of LD compressor stop no3 burner will stop automatically FO Auto Backup.
Cargo Tk Press L Manouvering Zone Low Gas Mode Both LD Comp Stop Only Base Gas Bnr Firing No3 Bnr Stop & Gas Mode & OR FO Auto Backup Order
1001854 / 0D / Page 37 of 93
Flowchart for Changeover GAS => Dual:

SEQ-13 Mode: GAS => Dual Condition for next step - Air Bias OK Action Start Start Permissive Terminate - IAS mode: Dual button from Monitor is pressed. - FO Auto backup Order OR - FG Inc Order (SEQ-9 Step 5, SEQ-10 Step 4)
Total Timeout: 5Min Set Air Bias Timeout : 1sec Error
- FO Control Vlv in Start Pos
Set FO Ctr Vlv To Start Pos Timeout : 10sec
Error
- Bnr1 Atm Stm vlv Opened or Bnr1 is OFF - Open Bnr2 Atm Steam Vlv & & - Close Bnr2 Stm Purg Vlv - Bnr2 Atm Stm vlv Opened or if GAS Bnr2 is ON Bnr2 is OFF & - Open Bnr3 Atm Steam Vlv & - Bnr3 Atm Stm vlv Opened or - Close Bnr3 Stm Purg Vlv Bnr3 is OFF if GAS Bnr3 is ON Timeout : 10sec
- Open Bnr1 Atm Steam Vlv & - Close Bnr1 Stm Purg Vlv if GAS Bnr1 is ON
Error
- GAS Mode - Boiler FO Vlv Opened - FO Burners no interlock active. - Burner mode = Auto - Number of GAS bnrs are 2 or more - Bnr Increase Seq Off & - Bnr Decrease Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Bnr Abnormal - Not Seq Jam - GAS PRESS > 0.1 bar
-Boiler Trip - FO Trip - GAS Trip
OR
- Bnr1 Stm Purge vlv Clsed or Bnr1 is OFF & - Bnr2 Stm Purge vlv Clsed or Bnr2 is OFF & - Bnr3 Stm Purge vlv Clsed or Bnr3 is OFF
- Check Steam Purg Vlv is Closed Timeout : 10sec
Error
- FO recirc Valve Close Cmd
Close FO Recirc Valve Timeout : 10sec
Error
- Bnr1 Dual Burning or Bnr1 is OFF & - Bnr2 Dual Burning or Bnr2 is OFF & - Bnr3 Dual Burning or Bnr3 is OFF & Waiting Timer 10sec
- Open Bnr1 FO Vlv 1&2 if GAS Bnr1 is ON - Open Bnr2 FO Vlv 1&2 if GAS Bnr2 is ON - Open Bnr3 FO Vlv 1&2 if GAS Bnr3 is ON Timeout : 10sec GAS => Dual Seq Failed Reset FO Control Valve to Start Position -Reset Air Bias -Reset FO Ctr V Start Pos
Error
End
1001854 / 0D / Page 38 of 93
Dual => FO: When mode switch is changed from dual to FO, the system will stop gas firing. Flowchart for Changeover Dual => FO:
SEQ-14 Mode: Dual =>FO Start Start Permissive Terminate - IAS mode: FO button from Monitor is pressed. OR
Condition for next step - GAS Press < 50mbar
Action Set Gas Extinguish Request to Gas Flow Controller Timeout : 180sec
Error
Stop GAS Bnr1 - GAS Burner 1 is OFF & Stop GAS Bnr2 - GAS Burner 2 is OFF & Stop GAS Bnr3 - GAS Burner 3 is OFF Timeout : 30sec Error
- Any FO burner On - Burner mode = Auto - Bnr Increase Seq Off - Bnr Decrease Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - FG => Dual Seq Off - FO Boost Up Seq Off - Not Bnr Abnormal - Not Seq Jam
&
-Boiler Trip - FO Trip
OR
Reset Gas Extinguish Request to Gas Flow Controller
Dual => FO Seq Failed - Reset Gas Extinguish Request to Gas Flow Controller
End
1001854 / 0D / Page 39 of 93
Low Load Gas Mode: Low Load Gas mode can be selected either in dual mode condition or in gas mode condition. This mode enables gas only firing during main turbine in maneuvering zone. Dual => Low Load Gas Mode: When LL gas mode is activated at dual mode, the boiler master will increase the calorie demand in order to increase gas pressure to over 0.1bar. When gas pressure is over the limit for changing to gas mode, then dual=>gas sequence is activated. After change to gas mode is complete boiler master low limit will be set depending on number of burners. Gas => Low Load Gas Mode: When LL gas mode is activated at gas mode, boiler master low limit will be set depending on number of burners. Note: Since Low Load Gas Mode sets a minimum boiler master demand main steam pressure might increase. In case main steam pressure is increased the dump control valve will open and keep the pressure at dump set point. Low Load Gas Mode Available: BMS Auto & 2 or 3 Bnr Firing & Dual or Gas Mode
1001854 / 0D / Page 40 of 93
Low Load Gas Mode Exit: FO Mode Pushbutton Depressed, or Dual Mode Pushbutton Depressed or Gas Mode Pushbutton Depressed or Steam Press Over 62.9bar or Dump control valve over 70% or Gas mode dropout (Fuel mode is changed from gas to other mode due to FO boost-up or back-up.)
Boiler Master Low Limit: During changeover at dual 2 bnr: 17 Gcal/h During changeover at dual 3 bnr: 26 Gcal/h At low load gas mode and gas only firing: 13 Gcal/h
1001854 / 0D / Page 41 of 93
4.6 Fuel Oil Boost UP

FO boost up sequence is available in GAS mode. The sequence is initiated in case of GAS master valve trip conditions.
SEQ-15 Fuel Oil Boost Up Start Start Permissive Terminate -FO Boost Up Order From Shd System
Condition for next step - If Bnr1 GAS firing: Bnr1 Atm Stm V Opened Bnr1 FO Vlv 1&2 Opened Bnr1 Prg Stm V Closed & - If Bnr2 GAS firing: Bnr2 Atm Stm V Opened Bnr2 FO Vlv 1&2 Opened Bnr2 Prg Stm V Closed & - If Bnr3 GAS firing: Bnr3 Atm Stm V Opened Bnr3 FO Vlv 1&2 Opened Bnr3 Prg Stm V Closed & - FO Recirc V Opened
Action Open: Bnr1 Atm Stm V if Bnr firing Bnr2 Atm Stm V if Bnr firing Bnr3 Atm Stm V if Bnr firing Bnr1 FoVlv1&2 if Bnr firing Bnr2 FoVlv1&2 if Bnr firing Bnr3 FoVlv1&2 if Bnr firing Close: Bnr1 Prg Stm V if not firing Bnr2 Prg Stm V if not firing Bnr3 Prg Stm V if not firing FO Recirc Vlv Force FO Control Vlv to "FO Boost Up Order" Position Timeout: 6 sec
- Burners Firing in GAS mode - All Bnr FO Valves Closed - FO Shutoff Vlv Opened - Boiler in Auto Mode
&
-FO Trip Error Close Bnr1 FO Vlv's & Air register if No Flame or Purge steam vlv not closed or Atomize steam vlv not open Close Bnr2 FO Vlv's & Air Register if No IR Flame or Purge steam vlv not closed or Atomize steam vlv not open Close Bnr3 FO Vlv's & Air Register if No IR Flame or Purge steam vlv not closed or Atomize steam vlv not open Error
Wait 15 Sec
- All Bnr GAS Vlv's Closed - Boiler Gas Valve Closed
Close: - All Bnr GAS Vlv's - Boiler GAS Valve Timeout: 10 sec
Relaease FO Boost Up Order Force Control
Relaease FO Boost Up Order Force Control
Alarm: Fuel Oil Boost Failed
End
1001854 / 0D / Page 42 of 93
4.7 Nitrogen Purge of Gas Supply Lines

Purging of gas supply lines can be done from the IAS operator stations. The following sequences are available: N2 Purge Master Line to Vent N2 Purge No1/2 Boiler Gas Header to Vent N2 Purge No1/2 Boiler Gas Burner to Furnace( by gas burner stop sequence). N2 Purge No1/2 Boiler Gas Header & Burner to Furnace
Vent Mast
Master gas valve
Gas Supply
GAS main line N2 purge valve
Vent
Vent
N2 Supply
GAS Control Valve Boiler GAS Valve Bnr 3 N2 Purge Valve
Hdr N2 Purge Vlv
GAS Control Valve Boiler GAS Valve
Bnr 1 N2 Purge Valve
Bnr 2 N2 Purge Valve
FWD (2) Burners on Stbd Boiler Burners on Port Boiler
FWD (2)
CNTR (1)
CNTR (1)
Hdr Vent Vlv
AFT (3)
AFT (3)
Hdr Vent Vlv
1001854 / 0D / Page 43 of 93
4.7.1 N2 Purging of Main Line to Vent

When the main line is purged, the line from the master gas valve outlet to each of the boiler gas valve inlets is purged with N2. Master N2 purging can be started when there are no gas burners firing in any boiler, the master gas valve is closed and both boiler gas valves are closed. The system will open the master vent valves and then open the master N2 purge valve. After purge time has elapsed the master N2 purge valve will close again. The main line vent valves will remain open. A status indication Master N2 purged will be set after successful sequence is performed. This status will be reset when the master gas valve closed indication disappears. This sequence will be performed automatic when the master gas valve is closed, but can also be manually started from a pushbutton on the IAS operator stations. Flowchart:
SEQ-16 Nitrogen Purging Main Line Condition for next step - Master Gas Valve Closed Action Check Master Gas Valve Closed Timeout : 50 sec Error Master GAS Valve Close Command Boiler 1 GAS Valve Closed Boiler 2 GAS Valve Closed No Gas Burners Active & Start Start Permissive Terminate - Master N2 purge from monitor(Remote) - Master GAS Valve Close Cmd OR
- Master Vent Valve 1 Opened & - Master Vent Valve 2 Opened
Open Master Vent Valves Timeout : 10 sec
Error
- Master N2 Purge Valve Opened
Open Master N2 Purge Valve Timeout : 10 sec
Error - Master GAS Valve Not Closed OR
Wait 90 Seconds
- Master N2 Purge Valve Closed
Close Master N2 Purge Valve Timeout : 10 sec
Error
Master N2 Purge Seq Failed - Master Vent Valve 1 Open - Master Vent Valve 2 Open - Master N2 Purge Valve Close
Set - Master GAS Valve Not Closed Reset
Set Master N2 Purged Status
End
1001854 / 0D / Page 44 of 93
4.7.2 N2 Purge of Gas Header to Vent

When the gas header is purged, the line from each boiler gas valve outlet to each burner gas valve inlet is purged with N2. The gas header can be purged when no gas burners are firing in that boiler and the boiler fuel gas valve is closed. The system will open the boiler header N2 vent valve and then open the header N2 purge valve. After purge time has elapsed the N2 purge valve will close again. The header N2 vent valve will remain open. A status indication header purged will be set. This status will be reset when the boiler fuel gas valve closed indication disappears. This sequence will be performed automatic when the boiler gas valve is closed and purge to furnace is not succeeded. The sequence can be manually started from a software pushbutton on the IAS operator stations if required.
Flowchart:
SEQ-17 Nitrogen Purging Boiler Header Condition for next step - Boiler Header N2 Vent Valve Opened Action Open Boiler Header N2 Vent Valve Timeout : 10 sec Error Error - Boiler GAS Vlv Closed - All Bnr GAS Closed - Boiler Header N2 Purge Valve Opened Open Header N2 Purge Valve Timeout : 10 sec Error & Start Start Permissive Terminate - Purge boiler hdr/bnr from monitor(Remote) - Boiler GAS Valve Close(SEQ-8,step4) OR
Wait 35 Seconds
- Boiler GAS Valve Not Closed
OR
- Boiler Header N2 Purge Valve Closed
Close Header N2 Purge Valve Timeout : 10 sec
Error
Set - Boiler GAS Valve Not Closed Reset
Set Boiler Header Purged Status
Header N2 Purge Seq Failed - Header Vent Valve Open - Header N2 Purge Valve Close
End
1001854 / 0D / Page 45 of 93
4.7.3 N2 Purge of Gas Burner to Furnace

When the gas burner is purged, the line from each burner gas valve outlet to each gas burner is purged with N2. Burner purge is performed automatically as a part of the gas burner stop sequence (SEQ-6). When the burner gas valve is closed and there is at least one flame in the furnace, the burner N2 purge valve will be opened. After purge time has elapsed the burner N2 purge valve will close again. A status indication Burner <x> purged will be set. This status will be reset when the burner gas valves closed indication disappears.
4.7.4 N2 Purge of Gas Header & Burner to Furnace

After gas firing is shut off the header and burners are purged to furnace. When the gas header is purged, the line from each boiler gas valve outlet to each burner gas valve inlet is purged with N2. The gas header can be purged when no gas burners are firing in that boiler and the boiler gas valve is closed. The master N2 purge valve and the burner N2 purge valves must also be closed. The system will open all burner gas valves and then open the header N2 purge valve. After purge time has elapsed the N2 purge valve and all burner gas valves will close again. The header N2 vent valve will be opened. A status indication header purged will be set. This status will be reset when the boiler fuel gas valve closed indication disappears. This sequence will be performed automatic when the boiler gas valve is closed, but can also be manually started from a software pushbutton on the IAS operator stations.
1001854 / 0D / Page 46 of 93
Flowchart:
SEQ-19 Nitrogen Purging Boiler Header & Bnr Condition for next step - Boiler Header Vent Valve Closed Action Close Boiler Header Vent Valve Timeout : 10 sec Error Start Start Permissive Terminate - Purge boiler hdr from monitor(Remote) - Purge request from Boiler Gas Vlv Close sequence (SEQ-8 step3) OR
- Any FO Bnr On - Boiler Gas Vlv Closed - All Bnr Gas Valves Closed - Burner N2 Purge Valves Closed
&
- Bnr1 GAS Valve 1&2 Opened OR FO Bnr1 Off & - Bnr2 GAS Valve 1&2 OpenedOR FO Bnr2 Off & - Bnr3 GAS Valve 1&2 OpenedOR FO Bnr3 Off
- Open Bnr1 GAS Valves if : FO Bnr1 On - Open Bnr2 GAS Valves if : FO Bnr2 On - Open Bnr3 GAS Valves if : FO Bnr3 On Timeout : 10 sec
Error
- Boiler Gas Vlv Not Closed
OR
- Boiler Header N2 Purge Valve Opened
Open Header N2 Purge Valve Timeout : 10 sec
Error
Wait 25 Seconds
- Boiler Header Vent Vlv Opened - All Bnr GAS Valves Closed - Boiler N2 Valve Closed
Open Header Vent Valve After 5 sec All Bnr GAS Valve Close After 10 sec Header N2 Valve Close Timeout :30 sec
Error
Header N2 Purge Seq to Furn Failed Set - Boiler GAS Vlv Not Closed Reset Set Boiler Header/ Burner Purged Status - All Gas Bnr Valves Close - Header N2 Purge Valve Close - Header Vent Valve Open
End
1001854 / 0D / Page 47 of 93
4.7.5 Main Line Vent Valves

Master vent valves are performed automatically as follows. Master vent valves are automatically closed when: 10 sec after master gas valve open command Master gas valve open limit switch is active.
Master vent valves are automatically opened when: 15 sec after master gas valve close command, or Master gas valve closed limit switch is active, & Both boiler gas valves closed
Master gas valve open command is as follows: Master gas valve open order is selected from monitor. This is possible when master gas valve interlock is not active (Not master gas valve trip).
Master gas valve close command is as follows: Master gas valve close order is selected from monitor. Master gas valve interlock is active (Master gas valve trip) Both boilers gas valve interlock are active (Both boiler gas valve trip)
1001854 / 0D / Page 48 of 93
5 BOILER CONTROL
5.1 Drum Water Level Control
The purpose of this controller is to keep the water level in boiler drum constant. This is done by controlling the feed water flow to the boiler in accordance with the steam flow from the boiler and with a correction from drum level measurement. The flow measurement and the level measurement are weighed, and then given as set point to the flow controller. In case of feed water flow transmitter is faulty, the backup controller will take over the control of the valve. The backup controller is a 2 element control based upon level measurement and steam flow measurement. The backup controller can also be activated by the operator if wanted. The level controller has following two set points and wanted set point can be selected from the IAS operator stations: Fixed level set point. Variable level set point dependent on the steam flow.
Super Htr
158B Safety Sensor
167B Steam Flow #1
FI
FI
167B Steam Flow #2
LI
High Sel
Boiler Drum
LI
Sel Switch
Feed Fwd
LC (PI)
F1
Setp
FC (PI)
Error 166B Drum Water Level Fixed level Setp
Par Select
Setp
Switch
Backup Controller
LC (PI)
Feed Fwd
Switch to backup if Feed w flow is faulty
Setp
F2
Valve char
FI Economizer Feed Water Pumps
1001854 / 0D / Page 49 of 93
Failsafe handling Cause Steam flow signal failure Feed water flow signal failure Level measurement signal fail Effect Steam flow value freeze Switch to backup controller Switch to safety sensor. If both control & safety sensor is failed then controller is set to manual mode, and operator must manually control the FW valve. Alarm Comments: Both sensors failed
Difference between No effect valve Command and ABU feedback > 10%
1001854 / 0D / Page 50 of 93
5.2 Main Steam Temperature Control

The purpose of this system is to maintain the main steam temperature constant at set point. The temperature controller set point can be selected from the IAS operator stations. Superheated outlet temperature is measured by two sensors and a high selector is used as process value for the controller. Steam flow and super heater 5 pass inlet temperature is used a feed forward action in order to obtain quick response at load changes.
129B SH Outlet Temp 1 TI 129B SH Outlet Temp 2 TI 119B SH 5 Pass In Temp TI 167B Steam Flow 1 FI 167B Steam Flow 2 FI Fuel Calorie Input FI
Hi Sel
Steam Temp => Vlv Opening Steam Flow => Vlv Opening
Hi Sel
Cal Inp => Vlv Min Op.
Normal 515 C Man Mode 500 C
Sw
Setp
PID
Feed Fwd
Hi Sel
20% 180 s
3rd Burner start
Hi Sel
FO or Dual Mode
130B Steam Temp C/V (Large)
133B Small Steam Temp C/V
Two steam temperature control valves are provided parallel. One is large, another is small. Small control valve is provided additionally with considering of boiler capacity. Additional small control valve is operated by fuel mode as initial plan. Action of small control valve is decided by function generator which is located between high selector and switch, as above figure.
1001854 / 0D / Page 51 of 93
Failsafe handling Cause SH Outlet Temp Sensor Failure SH 5 pass inlet temp sensor failure Steam flow sensor failure FO flow sensor failure GAS flow sensor failure Effect Temp Controller to Manual Value frozen in last readable value Value frozen in last readable value Value frozen in last readable value Value frozen in last readable value Both sensors failed Comments: Both sensors failed
5.3 Atomizing Steam Pressure Control

The purpose of this system is to control the atomizing steam pressure at the most suitable levels according to FO pressure. This system consist of a PID controller where set point is derived from the FO pressure.
242B Atom Press PI
231B FO Press PI
FO Press => Atom Setp
DO Press => Atom Setp
Swit ch Swit ch
Ign Val FO (6bar) FO Bnr's Off
Swit ch
Ign Val DO (6bar) FO Bnr's Off
DO Use
PID
Setp Follow
Tracking 50% at Gas Mode
226B Atomiz Press C/V
1001854 / 0D / Page 52 of 93
Failsafe handling Cause Atom Press signal fault FO press signal fault Effect Controller is set to Manual No effect Comments:
5.4 Steam Purge Pressure Control

The purpose of this system is to control the purge steam pressure at the most suitable levels.
362B Purge Press PI
0 1
2bar 1bar Burner Purge SP down at Burner Purging (SEQ-4 Status 8-12)
2bar
Any Burner Purge V/V Open
Setp
PID
Failsafe handling Cause Purge Press signal fault Effect Controller is set to Manual Comments:
1001854 / 0D / Page 53 of 93
5.5 FO Pump Discharge Pressure Control

The FO pump outlet pressure is maintained by controlling the recirculation. Set point to the controller is a high selection of main boiler 1 and main boiler 2 FO burner pressure.
MB1 FOPress (from Fuel Oil Control Loop) Hi Sel

FO Press => Setpoint
MB2 FOPress (from Fuel Oil Control Loop)
200B FOPump Press PI
All FO Bnr Stopped (8,5bar)
Switch
Setp
PID
FO Pump Stopped (80%) Switch 10%

20 s
FO Boost Seq Run
215B FOPump Press C/V
Failsafe handling Cause FO pump pressure signal fail MB1 FO pressure signal fail MB2 FO pressure signal fail Effect Controller is set to Manual No effect No effect If both boiler FO press signal fails then set point will be fixed. If both boiler FO press signal fails then set point will be fixed. Comments:
1001854 / 0D / Page 54 of 93
5.6 Steam Pressure Control

The purpose of this system is to maintain the steam pressure at outlet super heater at a constant value according to set point, normally at 60.3 bar. Set point is adjustable from IAS operator stations. The pressure control is done by controlling the total fuel flow and the combustion air flow to all burners. The air flow controller will lead during increasing demand At boiler start, steam up controller will bring boiler pressure up to set point at predefined rate. When 2 boilers are brought up to set point (steaming up finished) the master controller will automatically activate and take control. Boiler Master Controller. The boiler master controller consists of 3 controllers. Boiler 1 controller: - Steaming up, 1 boiler operation, FO ,Gas or air flow in manual. Boiler 2 controller: - Steaming up, 1 boiler operation, FO ,Gas or air flow in manual. Master controller: - 2 boilers parallel operation and FO ,Gas and air flow in auto. Load ratio A load ratio function is applied at master control. Operator may select a percentage load rate between the two boilers. This will affect the master calorie demand to FO, Gas and air flow controllers. Master Set point. Master set point is set manually, normally 60.3 bar. Dump controller set point is given a bias from master set point, normally master set point + 1 bar. In case of maneuvering mode or excess BOG mode master set point is automatically set down to master set point 1 bar (set down ramp is rapid, return to master ramp is slow).
1001854 / 0D / Page 55 of 93
165B MB1 Sream Press 1
165B MB1 Steam Press 2
167B MB1 Steam Flow 1
PI
PI
PI
PI
FI
FI
FI
FI
Hi Sel Hi Sel
Hi Sel
Hi Sel Hi Sel
Hi Sel
Steam Up Rate Master Setpoint Auto Set Down Set Down Bias FO Cal Input Gas Cal Input
Swit ch
Set
Trc
ed Fe
d Fw
PID
Steam-Up 0-50 Gcal/h
Set
PID
F ed Fe Trc
d w
MB2 Master Demand
Master 0-100 Gcal/h
Swit ch
Load Ratio
0-50 Gcal/h
Ratio Set Ratio Feedback 0-50 Gcal/h Other Boiler
Swit ch Low Lim

Low Load Gas Mode
Press => Max Load 0.00075 Gcal/kg Air Flow (kg/hr) Bias 1.1
Tracking Master : NOT (2 boiler paralell operation and FO,GAS,Air in Auto) Steam Up: FO or GAS or Air in Manual or Master Active
* * 0,5
Low Sel Low Lim
Boiler Demand
Failsafe handling Cause MB1 steam pressure signal failed MB2 steam pressure signal failed MB1 steam flow signal failed MB2 steam flow signal failed Effect Controller is set to Manual Controller is set to Manual Value freeze Value freeze Comments: Both signals failed Both signals failed Both signals failed Both signals failed
1001854 / 0D / Page 56 of 93
Fuel Oil Flow Controller Fuel flow controller set point is made by : Boiler master demand Actual Gas heat input. Burner min and max protection is made by set point limitation of flow controller. FO boost up function is implemented in order to decide correct FO flow in case of Gas trip.
231B FO Press 1 PI HI Sel A Swit ch
FO Press => FO Flow FG Flow => FO Flow
231B FO Press 2 PI
Gas Flow (from Gas flow control loop) Swit ch
Master Cal Demand Gas Cal Input 0 FO Boost Up Order Swit ch & OR 2nd FO Ign Set Req 3rd FO Ign Set Req Dual Mode
To Atomiz Press Control Loop To FO Pump Discharge Press Control Loop
All FO Bnr Off 0
Lo Sel
Max FO Bnr Flow No Of FO Bnr
FO Cal Value
No Of FO Bnr
X A PID
With Up/dwn Ramp
Swit ch Hi Sel
FO Bnr Exting Req
Min Press Control
FO Flow FO Cal Inp X FO Cal Value FO Boost Up Order PID Lo Sel Swit ch FO Recirc Vlv Opened FO Ignition , FO FO Ignition, Dual 1bnr FO Ignition, Dual 2bnr FO Ignition, Dual 3bnr
Setp
Swit ch
Min FO Flow 1 Bnr FO Min FO Flow 2 Bnr FO Min FO Flow 3 Bnr FO Min FO Flow 1 Bnr Dual Min FO Flow 2 Bnr Dual Min FO Flow 3 Bnr Dual Min FO Cal Inp
FO Cal Value
FO Ctr Vlv Force Swit ch
1001854 / 0D / Page 57 of 93
Failsafe handling Cause FO press signal failed Gas press signal failed Effect Manual mode No effect Comments: Both sensor failed
Fuel Gas Flow Controller Gas Flow is measured by differential press transmitter for Gas flow input (differential pressure between burner/Hdr), BOG pressure and BOG temperature. Controller set point is set from boiler master. Set point is defined as boiler master FO minimum flow. A separate minimum controller is provided in order to maintain Gas minimum flow FO boost up function is implemented in order to keep gas supply steady during FO ignition when master gas valve trip is activated.
1001854 / 0D / Page 58 of 93
249B Gas Press PI
238B BOG Temp TI
230B BOG Press PI
Gas Press => Gas Flow Master Cal Demand
FO Min Cal Input FO Cal Input
No Of Gas Bnrs
Swit ch OR
FO control Manual Gas Control Manual
& Lo Sel
0
OR
2nd FO Ign Set Req 3rd FO Ign Set Req Dual Mode
Max Gas Bnr Flow No Of Gas Bnr
Swit ch
All Gas Bnr Stop
/
To Air Flow Control To Fuel Oil Flow Control With Up/Dwn Ramp Flt
Gas Cal Value
Gas Flow Gas Cal Inp
Swit ch Hi Sel
Gas Bnr Exting Req
Min Gas Flow 1 Bnr
X
Gas Cal Value
Swit ch
Min Gas Flow 2 Bnr Min Gas Flow 3 Bnr Min Gas Flow At Bnr Inc
PID
Flow Controller
Setp
Min Flow Controller
PID
Hi Sel Swit ch
Gas Shut Vlv Closed Gas Ignition, 1bnr, Free Flow Gas Ignition, 2bnr, Free Flow
FO Boost Up Order
Gas Ctr Vlv Force
Swit ch
Gas Ignition, 3bnr, Free Flow Gas Ignition, 1bnr, LD Run Gas Ignition, 2bnr, LD Run Gas Ignition, 3bnr, LD Run
208B Gas Flow C/V
1001854 / 0D / Page 59 of 93
Failsafe handling Cause Gas press signal failed BOG press signal failed BOG temp signal failed GAS Flow signal failed Effect Switch to flow control No effect No effect Switch to pressure control Comments:
Air Flow Controller The set point for the air controller is calculated by the total calorie input (FO flow + Gas flow) multiplied by an air ratio. A feed fwd from boiler master demand is used in order to quickly response to load changes. The air ratio is automatically adjusted by an O2 controller. The O2 controller set point is variable with the boiler load. If wanted the air/fuel ratio can be adjusted manually. The air controller is built to lead during load increase.
1001854 / 0D / Page 60 of 93
GAS Flow
FO Flow
Burner Load
Flue Gas O2 O2
Air Flow PI Hi Sel Sel Sw
Air Flow PI
17.47
14
Bnr Load => O2 Content
Stby Fan Air Flow
+ A X Fuel/Air Ratio Set 0.5 - 1.5 Soot Blow Running 1.1 Air Bias ( Bnr Seq) 1.05
Excess Ratio
Calc
mbar => Kg/h Setp
PID
Range 0.9-1.1 Setp
> 40000 > 4000 & < 8000
Furn Prg OK Ign OK
X Not Man Zone Steam Flow > 80% 3 Bnr Run &
Fo llo w1
.0
PID
Sw i tch X
Vane Char
Ignition Set Furn purge Fdf Stop
X 1 bnr On (1.05) 2 bnr On (1.03) 3 bnr On (1.00) A X2 Low Sel
Sw i tch +
Boiler Master
Note:
O2 trim control is activated when the following conditions are established: Steam flow > 80% & 3 burners firing.
Failsafe handling Cause Air flow sensors failed FO press signal failed Gas press signal failed O2 Sensor failed Effect Air flow controller to manual No effect No effect O2 trim is bypassed Comments: Both sensors failed
1001854 / 0D / Page 61 of 93
5.7 Steam Dump Control

The main purpose of this system is to force the boilers to burn excess boil of gas generated in the cargo tanks. Secondary function is to prevent overpressure in the boilers. In case pressure at the steam outlet is above set point, the steam dump valves will start to open dumping the excess steam to the main condenser Excess BOG Controller. FO flow and Recommended BOG rate is calculated and transformed to an estimated steam flow equivalent which will be defined as the controller set point. The controller will use the dump control valves to keep the steam flow at set point. Max Gas Valve Controller. The excess dump controller output will be limited in case Gas control valve exceeds the max value (90%). Maneuver Dump Controller. Set point of this controller is made by master controller set point + bias. The controller will remain passive until boiler pressure exceeds the set point. When controller is activated it will remain active until boiler pressure is normal and output is 0.
1001854 / 0D / Page 62 of 93
167B 167B MB1 MB2 Steam Flow Steam Flow FI

BOG DUMP MODE GAS BNR RUNNING
165B MB1 Steam Press PI Hi Sel
165B MB2 Steam Press PI
FI Hi Sel
&
Not
MB1 Min FO Flow MB2 Min FO Flow Rec BOG 0-130 t/h Load Limit
Lo Sel
Swit ch
GCal => Stm Flow Set
PID
Dump Controller Lo Sel
PID
Set
Master Setpoint Bias 1bar
BOG Controller
Hi Sel Swit ch Swit ch
Crash Ast Boiler Master
MB1 FG Vlv Pos MB2 FG Vlv Pos Max FG Vlv Pos 95%
Hi Sel
t Se
MT Trip
PID Max FG Controller
Dump Pist Vlv Closed Dump C/V Lead/Follow Change Over
Dump Order => Spary V1 Contr
Dump Order => Spary V2 Contr
Hardware Function Generator by MHI
To IAS for Spray Vlv Control 331B Dump C/V #1 332B Dump C/V #2
Valve Ou t p u t 1 00 S p r ay1 S p r ay2
90
Du m p 1
Du m p 2
80
70
60
50 40
30
20
10 Du m p Cont r oll er Out pu t 10 20 30 40 50 60 70 80 90 100
1001854 / 0D / Page 63 of 93
Dump Piston Valve. Prior to steam dump control valves opening, the dump piston valve must be opened. This logic is calculated within the ABC by using dump control loop internal variables. In addition input from MT RCS is used. IAS calculates a dump available signal. If this signal is not present the dump piston valve will shut down.
Dump Controller: Set - Pv < 0.5 bar Dump controller output > 1% MT manovering zone MT Trip Off Delay 3min Dump Piston Vlv Open Order
&
OR
Dump Available From IAS
Failsafe handling Cause Steam press sensors failed Steam flow sensors failed MB1 Gas control vlv pos feedback failed MB2 Gas control vlv pos feedback failed MB1 FO flow signal failed MB2 FO flow signal failed Effect Controllers is set to Manual No effect No effect No effect No effect No effect Comments: 4 sensors failed
1001854 / 0D / Page 64 of 93
5.8 Flame Eyes

There are four flame eyes for each of the burners. Two flame eyes for both IR sensing and two for UV sensing. Flame is detected if one of the flame eyes is activated. When FO burning or GAS burning is active, then if one flame failure is detected then one flame eye fail alarm is provided. If four flame eyes failure are detected then FO and GAS burners are tripped. (Refer to "6 BOILER TRIP") IR flame fail alarm is suppressed if burner is only gas firing. UV flame fail alarm is suppressed if burner is FO or dual firing. Flame eye rack power fail and fan failure is sent to ABC for alarm. Principle drawing:
Timer Off 0 sec Flame Scanner 1 IR On Flame Scanner 2 IR On OR Flame Scanner 1 UV On Flame Scanner 2 UV On Flame ON
FO burner burning OR GAS burner burning Timer On
& OR F/E #1 IR Abnormal
& All Burner Stopped
1001854 / 0D / Page 65 of 93
5.9 FDF STBY Fan

Each main boiler has its own FDF which is normally used for combustion air supply. In addition there is a stby FDF which can be used in case normal FDF is failed. The stby FDF is common for the two boilers and can be used for only one boiler at the time. The ABC receives certain inputs for detecting that sbty fan and damper is selected and OK. Air flow sensors for stby FDF is input to common FS and the ABC logic will use these sensors for air flow control when stby FDF is selected. The output for vane control is switched to stby FDF vane by hardwired logic by MHI
No1 STBY Fan Mode No1 Side STBY Fan Dmr Open STBY FDF Run Low Or High OR Normal FDF Run Blr FDF Run & No1 STBY Fan Mode(DO)
1001854 / 0D / Page 66 of 93
5.10 Hot Start Valve

At hot start of boiler (steam press < 15 bar) the start-up valve is opened. When steam flow is low at boiler hot start (Steam up controller active) the start up valve is controlled according to steam flow. After steam up is finished the start up valve is permanently closed. Boiler condition Boiler stopped No burners firing Cold start of boiler Cold start needle valve opened & Boiler firing & steam press < 15bar Hot start of boiler Boiler firing & steam press > 15bar & steam flow < 2.5 t/h Hot Start of boiler Boiler firing & steam press > 15 bar & steam flow > 4 t/h
Boiler Firing Staem Press < 15 bar Set & OR Reset RS Hot Start Valve Open Order
Steam up valve Closed Opened
Opened
Closed
Staem Press > 15 bar Steam Flow < 2.5 t/h
&
OR
Staem Flow > 4.0 t/h
&
Timer ON 3 min
1001854 / 0D / Page 67 of 93
5.11 Viscometer Outlet Valve

When total (No.1 and No.2) FO flow is less than 900kg/h or No.1 boiler is gas mode or No.2 boiler is gas mode, viscometer outlet valve is opened.
1200 kg/hr No.1 Blr FO Flow
+
No.2 Blr FO Flow No.1 Blr Gas Mode No.2 Blr Gas Mode
LSE
Set 1200kg/hr Reset 1700 kg/hr
OR
Viscometer Valve Open
1001854 / 0D / Page 68 of 93
5.12 Fuel/Atomizing Valve Abnormal

HFO supply manual valve close LS DO supply manual valve close LS Atomizing steam supply manual valve close LS Atomizing air supply manual valve close LS No. HFO Close 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X X X X X X X X O O O O O O O O DO Close X X X X O O O O X X X X O O O O Steam Close X X O O X X O O X X O O X X O O Air Close X O X O X O X O X O X O X O X O Alarm Alarm Alarm Alarm Alarm Normal case 1 (Hot start condition) Normal case 2 (Transition condition) Alarm Alarm Trip case Normal case 3 (Cold start condition) Alarm Alarm Alarm Alarm Alarm X: open, O: close In case of No.10, FO shut off valve will be closed. In case of No. 6,7 and 11, condition is normal. In other case, alarm will be set. Remark
1001854 / 0D / Page 69 of 93
5.13 Output to Main Turbine

The boiler control calculates some outputs for the main turbine system.
Main Boiler 1 Drum Water Level Transmitter CompHi 220mm CompHi 200mm CompHi 180mm CompLo -200mm
10 s
MT Trip
10 s
MT Slow dow n
10 s
MT Program Interlock
10 s
MT Slow dow n
Main Boiler 2 Drum Water Level Transmitter CompHi 220mm CompHi 200mm CompHi 180mm CompLo -200mm
10 s
MT Trip
10 s
MT Slow dow n
10 s
MT Program Interlock
10 s
MT Slow dow n
Boiler Com m on MB1 Logick Boiler Firing & Both Boiler Trip
&
OR
One Boiler Trip
MB2 Logick
Boiler Firing
&
1001854 / 0D / Page 70 of 93
6 BOILER TRIP
The trip system is divided into five different categories. FO trip. Boiler trip. Boiler GAS trip. Master GAS trip. Burner flame fail trip.
Once the trip circuit is activated a holding circuit is activated and corresponding trip cause is flickering. Acknowledge button must be operated in order to confirm the trip cause, corresponding lamp is then steady lit. Trip circuit is still active. Acknowledge can be done from IAS or BGB whichever location is in command. When trip cause is acknowledged and trip cause is brought to normal, then trip can be reset by operating the respective system stop pushbutton. Trip circuit is de-activated. In case drum water level safety transmitter is faulty the control sensor can be selected for safety functions. This operation must be manually initiated by the operator. FO Trip. In case of FO trip condition is activated the FO supply to the boiler is tripped. Cause Atomizing steam press LL (3bar) FO temp LL (have bypass switch) (80 deg/C) FO Press LL (1bar) FO Pump Stop Fuel/Atomize Valve Abnormal Action - Boiler FO Shut Vlv Close - No1 burner FO vlv1&2 Close - No2 burner FO vlv1&2 Close - No3 burner FO vlv1&2 Close Reset Acknowledge pushbutton and Boiler FO shutoff vlv close pushbutton
1001854 / 0D / Page 71 of 93
Logic Diagram.
Atm Steam Press LL FO Temp LL FO Temp Bypass Sw itch & FO Trip &
FO Press LL &
OR
FO Pump Stop Any FO Bnr On Emergency Mode Fuel/Atomiz Valve Abnormal &
FO Trip OR Boiler trip Control position IAS IAS Blr FO Shutoff Vlv Close Push button Control position BGB BGB Blr FO Shutoff Vlv Close Push button & OR &
Set Reset RS
BoilerFO Shutoff Vlv Shutdow n Order Bnr1 FO Vlv1&2 Shutdow n Order Bnr2 FO Vlv1&2 Shutdow n Order Bnr3 FO Vlv1&2 Shutdow n Order
1001854 / 0D / Page 72 of 93
Boiler Trip. In case boiler trip condition occur is both FO and Gas system is tripped. Cause Drum water level HH (+240mm + 10s) by analogue sensor Drum water level LL (-240mm) by switch OR Drum water level LL (-240mm + 5s) by analogue sensor FDF stop All burner flame fail Emergency manual trip ECR Emergency manual trip BGB Main steam temp H (545deg/c) by analogue sensor Acknowledge pushbutton and Boiler Gas vlv close push-button reset Gas trip. Action - Activate FO trip - Activate Gas trip Reset Acknowledge pushbutton and Boiler FO shutoff vlv close pushbutton resets FO trip
1001854 / 0D / Page 73 of 93
Drum Water Level Transmitter
CompHi 240mm CompLo -240mm
10 s
5s
OR Boiler Trip & OR OR
Drum Water Level LL Float Sw itch No1 FD Fan Run Stby Fan Mode On Stby FD Fan Run High or Low Stby FD Fan Air Dmp OK Stby FD Fan Selected All Bnr Flame Fail Emerg Manu Trip ECR Emerg Manu Trip BGB Steam Temp Transmitter CompHi 545C & &
Boiler Gas Trip. In case of Gas trip condition is activated the Gas supply to the boiler is tripped. Cause BOG Press L (7mbar) BOG Press H (736mbar) Boiler Trip Condition Master Gas Valve Trip On + 15s Action - Boiler Hdr Vent Vlv Open - Boiler Gas Shut Vlv Close - No1 burner Gas vlv1&2 Close - No2 burner Gas vlv1&2 Close - No3 burner Gas vlv1&2 Close Reset Acknowledge pushbutton and Boiler Gas shutoff valve close pushbutton
1001854 / 0D / Page 74 of 93
BOG Press Transmitter
CompLo 0,007bar CompHi 0,736bar

90 s
&
&
OR Any Bnr Gas Vlv Opened

10 s
Boiler GAS Trip
Boiler Trip On
15 s
Master GAS Vlv Trip On
GAS Trip OR Boiler trip Blr GAS Vlv Close Pushbutton
Set Reset RS
Boiler Vent vlv Open Order Boiler GAS Vlv Shutdow n Order Bnr1 GAS Vlv1&2 Shutdow n Order Bnr2 GAS Vlv1&2 Shutdow n Order Bnr3 GAS Vlv1&2 Shutdow n Order
Master GAS Valve Trip. In case of Master GAS trip condition is activated the GAS supply to both boilers is tripped. Simultaneously FO boost up order is sent to each boiler. Cause E/R Vent Fan Failure Gas Duct Exh Fan Stop Gas leak detected Fire Detected BOG Temp LL (5deg/c) Master GAS Vlv Manu Trip Vapor Hdr Press LL BOG Htr Abnormal Master Gas Close Push Button Both Boiler trip Action - Master GAS Vlv Shutdown - Master N2 Vent Vlv Oppen Reset Acknowledge pushbutton and Master GAS Vlv close push-button
1001854 / 0D / Page 75 of 93
E/R Vent Fan Failure Gas Duct Exh Fan Stop Gas Leak Detected Fire detected BOG Temp LL Master Gas Vlv Manu Trip (ECR) Master Gas Vlv Manu Trip (BGB) Vapour Hdr Press LL BOG Htr Abnormal Master Gas Vlv Close PB Master GAS Vlv Trip OR OR
On-delay
10 s
FO Boost Up Order
Both Boiler Trip Both Blr GAS Vlv's Closed LS GAS Master Vlv Trip GAS Master Vlv Close Pushbutton Set Reset RS Master Vent vlv Open Order Master GAS Vlv Shutdown Order
1001854 / 0D / Page 76 of 93
Burner Flame Fail. In case flame is lost during burner firing, the burner FO and GAS supply is tripped.
Control Mode Manual Control Position IAS Control Position BGB Base Bnr IR 1&2 Failed Base Bnr UV1&2 Failed & IAS Base Bnr OFF PB & Set Reset RS Base Bnr Flame1 Fail Base FO Bnr Valve Close Base GAS Bnr Valve Close Base Bnr Atmise Valve Close Base Bnr Air Reg Close
OR
& BGB Base Bnr OFF PB No.2 Bnr IR1&2 Failed No.2 Bnr UV1&2 Failed & IAS No.2 Bnr OFF PB & Set Reset RS No.2 Bnr Flame1 Fail No.2 FO Bnr Valve Close No.2 GAS Bnr Valve Close No.2 Bnr Atmise Valve Close No.2 Bnr Air Reg Close
OR
& BGB No.2 Bnr OFF PB No.3 Bnr IR1&2 Failed No.3 Bnr UV1&2 Failed & IAS No.3 Bnr OFF PB & Set Reset RS No.3 Bnr Flame1 Fail No.3 FO Bnr Valve Close No.3 GAS Bnr Valve Close No.3 Bnr Atmise Valve Close No.3 Bnr Air Reg Close
OR
& BGB No.3 Bnr OFF PB &
Base Bnr Flame ON No.2 Bnr Flame ON No.3 Bnr Flame ON
&
OR
All Bnr Flame Fail
&
1001854 / 0D / Page 77 of 93
7 BOILER OPERATION PANELS

7.1 BGB Graphic Panel
The BGB graphic panel contains buttons for control of sequences and lamps for feedback. The buttons activates the same sequences as those used when operating from the IAS operator stations. Command transfer. In order to use the functions from the panel, command must be transferred from the control room to the BGB. BGB graphic panel lamp and switch functions.
Description
Type
Function
Orginator
By-pass Condition No1 or No2 Emerg Mode Common Emerg Mode AC 220V Source DC 24V Source MB1 + MB2 MB1 + MB2 MB1 + MB2 MB1 + MB2 Lamp Lamp Lamp Lamp Switch on BGB for selection of Emergency Mode Switch on BGB for selection of Emergency Mode Lamp on BGB Lamp on BGB BGB (by MHI) BGB (by MHI) BGB (by MHI) BGB (by MHI)
NoX Burner NoX Gas BNR On MB1 x 3 + MB2 x 3 Switch/Lamp Swich: Starts GAS Burner when Local Contr Position & manual mode. Lamp: - Flicker during start seq, - Fast Flicker when start error - Steady when burner is On NoX Gas BNR Off MB1 x 3 + MB2 x 3 Switch/Lamp Swich: Stops GAS Burner when Local Contr Position & manual mode. Also reset of start/stop error Lamp: - Flicker during stopt seq, - Fast Flicker when stopt error - Steady when burner is On FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
1001854 / 0D / Page 78 of 93
Description NoX FO BNR On MB1 x 3 + MB2 x 3
Type
Function
Orginator FS-10(MB1), FS-11(MB2)
Switch/Lamp Swich: Starts FO Burner when Local Contr Position & manual mode. Lamp: - Flicker during start seq, - Fast Flicker when start error - Steady when burner is On
NoX FO BNR Off
MB1 x 3 + MB2 x 3
Switch/Lamp Swich: Stops FO Burner when Local Contr Position & manual mode. Also reset of start/stop error Lamp: - Flicker during stopt seq, - Fast Flicker when stopt error - Steady when burner is On
FS-10(MB1), FS-11(MB2)
Flame Signal
MB1 x 2 + MB2 x 2
Indicator
Indicator
Flame condition indicator
BGB (by MHI)
FO Shut V/V Open MB1 + MB2 Switch/Lamp Swich: Send open command to FO shut valve Lamp: - Flicker during open time, - Fast Flicker if open failed - Steady when valve is open Close MB1 + MB2 Switch/Lamp Swich: Send close command to FO shut valve, also used FS-10(MB1), for FO/Boiler trip reset Lamp: - Flicker during close time, - Fast Flicker if close failed - Steady when valve is closed FS-11(MB2) FS-10(MB1), FS-11(MB2)
Furnace Purge Request MB1 + MB2 Switch/Lamp Switch : Lamp: Activates furnace purge sequence Switch On FS-10(MB1), FS-11(MB2) Lamp: BGB(by MHI) In Progress MB1 + MB2 Lamp Lamp On: Furnace purge in progress FS-10(MB1), FS-11(MB2) Complete MB1 + MB2 Lamp Lamp On: Furnace purge compleate OR Purge Status FS-10(MB1),
1001854 / 0D / Page 79 of 93
Description
Type
Function
Orginator FS-11(MB2)
BMS Position BGB Manual MB1 + MB2 Switch/Lamp Switch: Change burner operation to BGB location Lamp: Burner operation at BGB On IAS MB1 + MB2 Switch/Lamp Switch: Change burner operation to IAS Lamp Burner operation at IAS On FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
Alarm Boiler Trip MB1 + MB2 Lamp Boiler trip active or nor reset FS-10(MB1), FS-11(MB2) Atm Press Low MB1 + MB2 Lamp Atm press low active FS-10(MB1), FS-11(MB2) FO Press Low MB1 + MB2 Lamp FO press low active FS-10(MB1), FS-11(MB2) Manual trip MB1 + MB2 Lamp Boiler Manual Trip active FS-10(MB1), FS-11(MB2)
ABC Position BGB MB1 + MB2 Switch/Lamp Switch: Change control loop operation to BGB location Lamp: Control loop operation at BGB On IAS MB1 + MB2 Switch/Lamp Switch: Change control loop operation to IAS Lamp Control loop operation at IAS On FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
GAS Firing
MB1 + MB2
Lamp
GAS firing condition
FS-10(MB1), FS-11(MB2)
Feed water motor valve Open MB1 + MB2 Switch/Lamp Switch: Send open command to feed water motor valve control panel. Lamp: - Flicker during open time - Fast flicker if opened failed FS-10(MB1), FS-11(MB2)
1001854 / 0D / Page 80 of 93
Description
Type
Function
Orginator
- Steady when valve is open

Close MB1 + MB2 Switch/Lamp Switch: Send close command to feed water motor valve control panel. Lamp: - Flicker during close time - Fast flicker if closed failed - Steady when valve is closed FS-10(MB1), FS-11(MB2), FS12,(Com) FDF Start MB1 + MB2 + Switch Common Stop MB1 + MB2 + Switch Common Run MB1 + MB2 + Lamp Common Switch: Send start command to group starter panel via IAS. Switch: Send stop command to group starter panel via IAS. Lamp: Steady when FDF is Running. FS-10(MB1), FS-11(MB2)
Aux Feed Water Pump Start Common Switch Switch: Send start command to group starter panel via IAS. Stop Common Switch Switch: Send stop command to group starter panel via IAS. Run Common Switch Lamp: Steady when motor is Running. FS12,(Com) FS12,(Com) FS12,(Com)
Seal Air Fan Run (No1/2) Common Lamp Lamp: Steady when fan is Running. FS12,(Com)
1001854 / 0D / Page 81 of 93
7.2 Manual Loader Functions

The graphic panel at the BGB contains functions for manual control of each control valve. The IAS output (4-20mA) for control valves are connected to an ABU (Analogue Backup Unit). Normal mode. Each control valve or FDF vane can be manually controlled from either BGB graphic panel or from IAS operator stations. In normal mode the 4-20mA control signal from IAS is passed to the actuator. (Except for purge C/V and small Steam temp C/V) Emergency mode. In this case the IAS 4-20mA control signal is neglected and BGB increase/decrease order is operating the ABU output directly. The following control loops can be controlled from the local control panels Control of atomizing stem control valves.(MB1 & MB2) Control of the super heater temperature control valves.( MB1 & MB2) Control of Fuel gas control valves. (MB1 & MB2.) Control of the fuel oil control valves. (MB1 & MB2.) Control of the fd-fan inlet vanes. (MB1 & MB2) Control of the feed water valves. (MB1 & MB2.) Control of dump control valve (common for both boiler) Control of FO pump pressure control valve (common for both boilers) Note: ABU units are MHI supply.
1001854 / 0D / Page 82 of 93
ABC Position
IAS BGB OR Emerg mode Set Reset RS Not IAS BGB
Manual/Auto Selection
ABC Position "BGB" & BGB A & OR & OR Set Reset RS Not Auto Manual
BGB M ABC Position "IAS" IAS A (Sow button)
IAS M (Sow Button) Emerg mode
&
Inc / Dec Prinsipple

Manual
lec Se Trc t
PID
c Tr e lu Va
Man/Auto Selection "Manual" ABC Position "BGB" &
+ & Inc +/-
& Dec Emerg mode ABU Feedback(4-20mA) Sel Sw
Output to ABU 4-20mA
1001854 / 0D / Page 83 of 93
7.3 Emergency Operation

Note: This is outside of IAS, MHI supply
7.3.1 No.1 or No.2 part

case of failure of both controllers (active/standby) for No.1 or No.2 part, emergency operation mode is performed in following manner. 1) Air flow control valve should be fully closed. And the forced draft fan shall be started. 2) If emergency mode switch for common part is selected to emergency mode then FO pump discharge press control valve should be opened at about 50%. And the FO burning pump shall be started. After starting of FO burning pump, FO pump discharge press should be adjusted at a suitable pressure (15-20bar). 3) Change operation mode switch from "NOR" to "PURGE". Open fully (above 70%) air flow control valve. Differential press between wind box and furnace should be confirmed (above 15mbar). Furnace purge should be conducted until turning "Purge Finish" lamp on. 4) Change emergency mode from "PURGE" to "BURN". 5) Air flow control valve should be set at ignition position. (About 5%) 6) FO flow control valve should be set at ignition position. (About 20%) 7) Atomizing press control valve should be set at suitable position. (About 30%) 8) Turn FO shut V/V switch from "CLOSE" to "OPEN". 9) Turn igniter switch from "OFF" to "ON". 10) Turn FO V/V switch from "CLOSE" to "OPEN". FO V/V "OPEN" position should be kept until establishment of flame. However, it must not exceed 10 seconds. 11) Atomizing press should be kept at 8bar. 12) FO and Air flow should be adjusted manually, to keep safe combustion. 13) When second burner start, fuel oil press should be exceeded 10bar. And same as above item 12) and 13).
Note : If burner does not ignite by the above process, repeat operation from the above 3). Note : If drum water level low-low with float switch is detected, acknowledge button on BGB should be depressed.
1001854 / 0D / Page 84 of 93
7.3.2 Common Part

In case of failure of both (active/standby) controllers for common, emergency operation mode is performed in following manner. 1) Change operation mode switch from "NOR" to "EMERG". 2) FO pump discharge press should be adjusted at suitable pressure (15-25bar). 3) If dump control is needed, dump control valve should be adjusted at a suitable position.
8 SOOT BLOWING SEQUENCES

The soot blower sequences are provided within the IAS. Operations are done from the IAS monitors. Each boiler are equipped with 2 sequence possibilities, Boiler & economizer or economizer. In addition each blower can be started locally. The software consists of many subsequences, one for each blower. A main sequence call up respective subsequence during auto operation. Local operation call each subsequence directly. Operation. Operation is done from IAS monitors. Following operation modes are prepared: NO1 MAIN BOILER NO2 MAIN BOILER BOTH BOILERS
After selection of operation mode the sequence can by started. Following sequence selections are prepared: SEQ START ECO START Bypass Function Bypass function is performed manually or automatically. Manual function is active by selecting the corresponding bypass push buttons of IAS. Auto function is as follows. When "SEQ START" or "ECO START" function is running, if trouble occurs then corresponding soot blower is bypassed automatically.
1001854 / 0D / Page 85 of 93
Emergency retract If long soot blower forward sequence is active then the sequence is stopped. And the long soot blower retract sequence is stated. If long soot blower is not active or complete then "steam supply valve" is closed and "drain valve" is opened. If rotary soot blower sequence is active then the sequence is continued to the end position. Local Control. Local control is active by changing the control location from IAS to Local. Then start order will be active by depressing the "BOTH BLR" push button of IAS. After depressing the "BOTH BLR" push button of IAS, "steam supply valve" open and "drain valve" close. Operator can start the soot blower by depressing the corresponding Soot Blower push button. The subsequences Long Soot Blower and Rotary Soot Blower as described below is activated directly by the operator.
1001854 / 0D / Page 86 of 93
8.1 Long Soot Blower Sequence

This sequence can be called from SEQ START sequence or by local command. The blower will first run fwd until retract position is received. Then reverse rotation order is active until stop limit switch is received. An emergency retract function is applied. If emergency retract command is activated the run fwd order is cancelled and retract order is activated. Retract order will remain until stop limit switch is received. A maximum timer for retract order is applied.
Start Condition for next step - Blower Fwd Running ON & - Stop position OFF Start Start Permissive Terminate - Start Req from Soot Blow Auto Seq - Start Req from Local. OR
Action Start Fwd Timeout : 5 sec Error - Staem Valve Open - Not Emerency Retract On - Not Reverse Position - Not Steam Press Low - Not Emergency - Not Motor Overload - Not Reverse Run if Auto Seq - Boiler Load < 50 %
- Blower Retract Position ON & - Blower Fwd Running OFF
Reset Fwd Start at Retract position Timeout : 250 sec
Error
&
- Blower Rev Running ON & - Retract Position OFF
Start Reverse Timeout : 5 sec
Error - Emergency Retract ON - Steam press low & 30 Sec After Vlv Open - Steam supply valve abnormal if Auto Seq OR - Boiler trip - Auto Seq Fail - Motor Overload
- Blower Stop Position ON - Blower Rev Running OFF
Reset Rev Start at Stopt position Timeout : 250 sec
Error
- Reset Run Fwd Order - Set Rev Order if not stop position - Set Alarm - Set Bypass if Auto Seq
End
8.2 Rotary Soot Blower Sequence

This sequence can be called from SEQ START sequence, ECO START sequence or by local command. The blower will run until stop position is received. Then run order will be switched off.
1001854 / 0D / Page 87 of 93
Start
- Start Req from Soot Blow Auto Seq - Start Req from Local.
OR
Condition for next step - Blower Running ON & - Stop Position OFF
Action Start Blower Timeout : 5 sec Error
- Stop Position ON & - Blower Running OFF
Stop Blower at Stop position Error Timeout : 60 sec
- Motor Overload - Boiler Load < 50 %
&
- Motor Overload - Boiler Trip - Auto Seq Fail
OR
- Reset Run Order - Set Alarm - Set Bypass if Auto
End
8.3 Boiler & Economizer Soot Blower Sequence

This sequence makes use of Long soot blower sequence and rotary soot blower sequence in order to make a complete soot blower sequence. Each boiler can be soot blower separately or both boilers can be blower in serial. Once Steam supply valve opens, this valve keep open until all sequence finish AND all long soot blower in normal stop position. When long soot blower is stuck in travelling, steam supply valve keep open.
1001854 / 0D / Page 88 of 93
Flowchart for No.1 or No.2 boiler sequence

Start Condition for next step - Steam Vlv Opened Start Start Permissive Terminate - Start from Monitor(IAS) OR
Action Open Steam Vlv Timeout : 40 sec Close Other Blr Drain Valve Timeout : 10 sec Error - Control position IAS - No1 or No2 Boiler Select - Not ECO START - Not other BLR SEQ START - Not other BLR ECO START - Not motor over load - Not Soot Blower abnormal - Not Emergency retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
- Other Boiler Drain Valve Closed
Error
&
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec Start L1 If not Bypass ON Timeout : 2 sec Wait, L1 blowing Timeout : 500 sec Start L2 If not Bypass ON Timeout : 2 sec Wait, L2 blowing Timeout : 500 sec Start R1 If not Bypass ON Timeout : 2 sec Wait, R1 blowing Timeout : 60 sec Start R2 If not Bypass ON Timeout : 2 sec Wait, R2 blowing Timeout : 60 sec Start R3 If not Bypass ON Timeout : 2 sec Wait, R3 blowing Timeout : 60 sec Start R4 If not Bypass ON Timeout : 2 sec Wait, R4 blowing Timeout : 60 sec Start R5 If not Bypass ON Timeout : 2 sec Wait, R5 blowing Timeout : 60 sec Start R6 If not Bypass ON Timeout : 2 sec Wait, R6 blowing Timeout : 60 sec Close Steam Valve if all long blower in normal stop position & Open Drain Vlv 1&2 Timeout : 10 sec End
Error
- L1 Seq Run OR - Bypass ON - L1 Seq Run for 364 sec OR - L1 Seq Not Run - L2 Seq Run OR - Bypass ON - L2 Seq Run for 388 sec OR - L2 Seq Not Run - R1 Seq Run OR - Bypass ON - R1 Seq Run for 38 sec OR - R1 Seq Not Run - R2 Seq Run OR - Bypass ON - R2 Seq Run for 38 sec OR - R2 Seq Not Run - R3 Seq Run OR - Bypass ON - R3 Seq Run for 18 sec OR - R3 Seq Not Run - R4 Seq Run OR - Bypass ON - R4 Seq Run for 38 sec OR - R4 Seq Not Run - R5 Seq Run OR - Bypass ON - R5 Seq Run for 38 sec OR - R5 Seq Not Run - R6 Seq Run OR - Bypass ON
Bypass
Error
- Emergency Retract ON - Steam press low & 30 sec after eam valve open - Steam supply valve abnormal - Boiler Trip - AC 440V Failure
OR
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
- Terminate all soot blower sub sequences - Close steam Vlv if all long blower in normal stop position - Open No1 MB Drain Vlv
- R6 Seq Not Run
Error
- Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
Error - Open No2 MB Drain Vlv - Set Alarm
1001854 / 0D / Page 89 of 93
Flowchart for both boiler sequence

Start Condition for next step - Steam Vlv Opened & Start Start Permissive Terminate - Start from Monitor(IAS) OR
Action Open Steam Vlv Timeout : 40 sec Close No.2 Blr Drain Valve Timeout : 10 sec Error - Control position IAS - Both Boiler Select - Not ECO START - Not other BLR SEQ START - Not other BLR ECO START - Not motor over load - Not Soot Blower abnormal - Not Emergency retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
- No.2 Blr Drain Valve Closed
Error
&
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No1 Boiler Blower Sequence L1,L2,R1,R2,R3,R4,R5,R6 Open No.2 Boiler Drain Vlv Timeout: 10 sec
Error
- No.2 Blr Drain Valve Opened
Error
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam supply valve abnormal - Boiler trip - AC 440V Failure
OR
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No2 Boiler Blower Sequence L1,L2,R1,R2,R3,R4,R5,R6
Error
Close Steam Valve if all long blower in normal stop position & Open Drain Vlv 1 & 2 Timeout : 10 sec
- Terminate all soot blower sub sequences Error - Close steam Vlv if all long blower in normal stop position - Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
8.4 Economizer Soot Blower Sequence

This sequence makes use of rotary soot blower sequences in order to make a complete soot blower sequence. Each boiler can be soot blower separately or both boilers can be blower in serial.
1001854 / 0D / Page 90 of 93
Flowchart for No.1 or No.2 boiler sequence

Start Condition for next step - Steam Vlv Opened Start Start Permissive Terminate - Start from Monitor(IAS). OR
Action Open Steam Vlv Timeout : 40 sec Close Other Boiler Drain Valve Timeout : 10 sec Error - Control position IAS - Not SEQ START - Not other Blr SEQ START - Not other Blr ECO START - Not moter over load - Not soot blower abnormal - Not Emergency Retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
- Other Boiler Drain Valve Closed
Error
&
Timer 180s
- Steam Press OK
Check Steam Press OK Timeout : 2 sec Start R3 If not Bypass ON Timeout : 2 sec Wait, R3 blowing Timeout : 60 sec Start R4 If not Bypass ON Timeout : 2 sec Wait, R4 blowing Timeout : 60 sec Start R5 If not Bypass ON Timeout : 2 sec Wait, R5 blowing Timeout : 60 sec Start R6 If not Bypass ON Timeout : 310 sec Wait, R6 blowing Timeout : 60 sec Close Steam Valve & Open Drain Vlv 1 & 2 Timeout : 10 sec
Error
- R3 Seq Run OR - Bypass ON - R3 Seq Run for 18 sec OR - R3 Seq Not Run - R4 Seq Run OR - Bypass ON - R4 Seq Run for 38 sec OR - R4 Seq Not Run - R5 Seq Run OR - Bypass ON - R5 Seq Run for 38 sec OR - R5 Seq Not Run - R6 Seq Run OR - Bypass ON
Bypass
Error
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam supply valve abnormal - Boiler Trip - AC440V Failure
OR
Bypass
Error
Bypass
Error
Bypass
- R6 Seq Not Run
Error
- Terminate all soot blower sub sequences - Close steam Vlv
Error
- Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
1001854 / 0D / Page 91 of 93
Flowchart for both boiler sequence

Start Condition for next step - Steam Vlv Opened Start Start Permissive Terminate - Start from Monitor(IAS) OR
Action Open Steam Vlv Timeout : 40 sec Close No.2 Blr Drain Valve Timeout : 10 sec Error - Control position IAS - Not ECO START - Not other BLR SEQ START - Not other BLR ECO START - Not motor over load - Not Soot Blower abnormal - Not Emergency retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
- No.2 Blr Drain Valve Closed
Error
&
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No1 Boiler Blower Sequence R3,R4,R5,R6 Open No.2 Boiler Drain Vlv Timeout: 10 sec
Error
- No.2 Blr Drain Valve Opened
Error
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam supply valve abnormal - Boiler Trip - AC 440V Failure
OR
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No2 Boiler Blower Sequence R3,R4,R5,R6
Error
Close Steam Valve & Open Drain Vlv 1 & 2 Timeout : 10 sec
- Terminate all soot blower sub sequences Error - Close steam Vlv - Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
1001854 / 0D / Page 92 of 93
9 ATTACHMENTS
- Parameter List. (will be issued later) - ABC Operator Manual. (will be issued later)
1001854 / 0D / Page 93 of 93

Mitsubishi Boiler Control

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Mitsubishi Boiler Control

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PLAN RECORD ISO

METRIC SCREW THREDS

REVISIONS NO. DESCRIPTION (DATE)

A4 94 A3 0 TOTAL 95 SHEETS WITH COVER

DAEWOO H.NO.2227 / 2228 / 2235

T. Yuki Y. Ono K. Saito

Functional Design Specification for Boiler Control

MITSUBISHI HEAVY INDUSTRIES, LTD.

Project: Product Synopsis:

5.10 5.11 5.12 5.13 6

RIO SBRP SP SVC SW TG VDU

1.2 Flowchart symbols

This symbol represents a decision or switching type function

This symbol represents a named process, such as a subroutine.

This symbol represents data input by manual means

This symbol represents a process performed by operator or automatically by process event.

Indicates a crossreference within the same page of the flow chart.

This symbol represents the end of a program flow.

This symbol represents a data that is displayed for human use.

This symbol represents a delay/timer

Figure showing general arrangement:

IAS Ethernet HUB B

MB1 Control Cabinet

MB2 Control Cabinet

Boiler Common / Soot blowers Cabinet

Analogue control sensors

Analogue control sensors

Flame scanner #1 MT Trip/Pwr Reduction

Flame scanner #1 MT Trip/Pwr Reduction

Analogue Control Sensors Analogue Control Vlv's

Analogue Control Sensors Analogue Control Vlv's

Analogue Control Sensors Analogue Control Vlv's

Manual Loader Operator Panel

Manual Loader Operator Panel

Common Vlv's Operator Panel Others

Common Vlv's Operator Panel Others RIO

Soot Blower Control

Common Vlv's Operator Panel

Common Vlv's Operator Panel RIO Soot Blower Control

Operator Panel RIO Soot Blower Control

No1 Burner Control

No1 Burner Control RIO Soot Blower Control

No3 Burner Control

No3 Burner Control

3.2 Burner Management

3.3 CPU Redundancy

3.4 Power Distribution

Process Station Cabinet Main Supply Emerg Supply

BGB 220V AC 24V DC RIO Units 220V AC 24V DC

4.1 Fuel Oil Burning

Flowchart for starting fuel oil burners, the first FO burner:

- Boiler Purged Status Set

Start Furnace Purge Sequence (SEQ-2) Timeout : 6 min

- Fd Fan Vane In Start Pos(2-6%)

- Selected Bnr Register Opened & - Not Selected Registers Closed

- FO Recirc Valve Closed

Close FO Recirc Valve Timeout : 10 sec

- FO Ctr Vlv In Start Pos(15-21%)

Set FO Ctrl Vlv To Start Pos(18%) Timeout : 20 sec

Check Air Rate & FO Press & FO Temp Timeout : 60 sec

- All Flames OFF Waiting Timer: 1s

Check All Flames are OFF Timeout : 5 sec

Error - Set Alarm - Close Burner Fo Valve's

- Igniter Deactivated & - Igniter Retracted Waiting timer 7s