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This power plant has two boilers operating on the waste heat from the cement kilns:-
1. One no PH Boilers generating steam with the exit gases from the Pre heater kiln
2. One AQC Boilers generating steam with exit gases from grate cooler kiln
The operation write up is intended to cover the operation philosophy for the inlet, outlet
and bypass motorized dampers for safe and efficient operation of the boilers. The
complete logic for the damper operation of these dampers will be implemented in
customer DCS system.
The write up here will deal with one PH boiler and one AQC boiler damper logic.
There are three motorized ON/OFF dampers which will act as a group.
All these dampers will also have manual operation facility from the customer DCS system
For group operation, dampers 11-XV-162(Boiler bypass damper) / 11-XV-160 (Boiler inlet
damper) / 11-XV-161 (Boiler outlet damper) will act as a group and open/close
sequentially in case of boiler trip. When boiler is brought into service mode, the dampers
are brought into service one by one ensuring the permissive.
The gas Inlet, Outlet and Bypass dampers 11-XV-160, 11-XV-161 and 11-XV-162
respectively are to be controlled from customer DCS system manually. This damper shall
also have end position limit switches like the OPEN/CLOSE. The CLOSE limit switch shall
be field adjusted such that damper cannot be fully closed. Customer DCS operator will
manually open11-XV-162 ( Bypass damper-inching type ) partially from DCS to maintain
the exit temperature, whenever higher exit temperatures are required based on
cement process requirements.
Boiler trip logic is implemented in TL control system and the CAUSES for Boiler trip are as
follows:-
i) Recirculation pump trip
ii) LP drum low low
iii) LP drum level high high
iv) HP drum low low
v) HP drum low high high
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In case Boiler trip is initiated in TL Control system, following EFFECTS will be initiated:-
i) One Digital output from TL control system to customer DCS system (11-
PHTRIP-001=Incase BLR trip condition, becomes 1 to 0) to initiate group
bypass for the dampers 11-XV-162, 11-XV-160, 11-XV-161.
Step-1
Permissive – 11-PHTRIP-001=becomes 1 to 0.
Action: Force Open damper 11-XV-162 (bypass damper) - Open command until getting
OPEN F/B.
Wait time: 40-60 sec (To be adjusted at site)
Step-2
Permissive – 11-XV-162 (Bypass damper) open sensed by open limit switch
Action: - Close damper 11-XV-161 (Outlet damper)
Wait time- 40-60 sec (To be adjusted at site)
Step-3
Permissive: Damper 11-XV-161 (Outlet damper) is closed sensed by closed switch
Action: Close damper11-XV-160 (Inlet damper)
Wait time – 40-60 sec (to be set at site)
Step-4
Permissive: Bypass sequence complete. (One no Digital Output to be generated from
Customer DCS to TL control system), Digital O/P Tag: 11-BYP-002, (Where complete=1)
Action: Initiate RAV trip/stop sequence after T3 (30 min) time delay. RAV trip/stop
sequence logic is to be implemented in TL control system along with drag chain conveyor
logic. Trip sequence is as follows.
During bringing the boiler in operational mode, we recommend that the dampers be
manually opened /closed one by one instead of running on auto-sequence.
Common Permissive for Damper Opening operation are :( Common permissive
logic shall be implemented in TL Control system)
a. Boiler is ready for Damper opening Operation.
If 11-PHRDY-001 shall become o to 1 when
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Step-1
Permissive: 11-XV-162 (Bypass damper) open (sensed by open limit switch)
Action: Open 11-XV-160 (Inlet damper) .
Step-2
Permissive: 11-XV-160 (Inlet damper) is open (sensed by open limit switch) & Boiler RDY
(11-PHRDY-001).
Action: Open D3 (Outlet damper)
Wait till 11-XV-161 (Outlet damper) open feedback received.
Step-3
Permissive: 11-XV-160 and 11-XV-161 open
Action: Close 11-XV-162 (Bypass damper gradually from Customer DCS till minimum
position is reached sensed by limit switch.
Note: The closed limit switch shall be set at around 10% opening such that it cannot close
fully. This is to ensure that there is no build-up of dust on the damper 11-XV-162.
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Subsequent to stoppage of all RAV’s, the DCC will be stopped. The sequence shall be as
follows.
11-M-711/712/713/714/715 11-M-716 (with 5 min delay) 11-M-717 (with 5 min
delay) 11-M-718 (with 5 min delay).
PH Boiler:
Force Close & Open condition:
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For AQC Boiler-1, the gas from the (Air quench) grate cooler kiln have two paths:-
For AQC-1 boiler, the dampers 12-XV-165 (Bypass damper), 12-XV-160 (Inlet damper),
and 12-XV-161 (Outlet damper) are motorized multilouver dampers and controlled from
customer DCS system.
For group operation, dampers 12-XV-160, 12-XV-161, 12-XV-165 will act as a group and
open/close sequentially in case of boiler trip. When boiler is brought into service mode,
the dampers are brought into service manually one by one ensuring the permissive.
Boiler trip logic is implemented in TL control system and the CAUSES for Boiler trip are as
follows:-
i) LP drum low low
ii) HP drum level Low
iii) LP drum level high high
iv) HP drum level high high
In case Boiler trip is initiated in TL control system, following EFFECTS will be initiated:-
a. One Digital output (12-AQCTRIP-001=Incase BLR trip condition, becomes 1 to 0) to
initiate group bypass for the dampers 12-XV-160, 12-XV-161, 12-XV-165.
b. Initiate RAV trip sequence after 30 minute time delay. (RAV trip sequence logic to
be implemented in TL control system along with Drag chain conveyor logic.)
The bypass sequence of dampers can be initiated manually from customer DCS by
operator or when boiler has tripped (if 12-AQCTRIP-001=becomes 1 to 0). The
completion of the sequence will ensure that the hot gases are bypassed to ESP suction
bypassing the boiler.
Step-1
Permissive - 12-AQCTRIP-001= Becomes 1 to 0
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Action: Force Open damper 12-XV-165 (Bypass damper) by forcing Open command until
getting OPEN F/B
Wait time: 40-60 secs (to be adjusted at site)
Step-2
Permissive – 12-XV-165 (Bypass damper) open sensed by open limit switch
Action:- Close damper 12-XV-161 (Outlet damper)
Wait time- 40-60 secs (to be adjusted at site)
Step-3
Permissive: Damper 12-XV-161 (Outlet damper) is closed sensed by closed switch
Action: Close damper 12-XV-160 (Inlet damper)
Wait time – 40-60 secs ( to be set at site)
Step-4
Permissive: Bypass sequence complete (One no Digital Output to be generated from
Customer DCS to TL control system), Digital O/P Tag: 12-BYP-002. (Where complete=1)
Action: Initiate RAV trip/stop sequence after 30 min time delay. (RAV trip/stop sequence
logic is to be implemented in PPPLC along with Drag chain conveyor logic.).Trip sequence
shall be as follows.
During bringing the boiler in operational mode, we recommend that the dampers be
manually opened /closed one by one instead of running an auto-sequence.
Permissive for all following actions.
Step-1
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Step-2
Permissive: 12-XV-160 (Inlet damper) is open (sensed by open limit switch)
Action: Open 12-XV-161 (Outlet damper)
Wait till 12-XV-161 open feedback received.
Step-3
Permissive: 12-XV-160 and 12-XV-161 open
Action: Close 12-XV-165 (Bypass damper) gradually till minimum position is reached
sensed by limit switch.
Stopping of the group of RAV’s can be initiated by automatic stopping sequence or can be
manually closed one by one after the boiler has tripped or shutdown.
RAV stopping sequence can be initiated:-
-Manually by operator OR
-Automatically when the boiler has tripped. (i.e. 12-AQCTRIP-001=becomes 1 to 0 )
During auto sequence, the first All RAV is tripped after a delay of time 30 min.
Subsequent to stoppage of all RAV’s and DCC, the DO from PPPLC shall be triggered to 0
(i.e 12-AQCBLR-RDY= becomes 1 to 0).
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AQC Boiler-1:
Force Close & Open condition:
Note: All the timers shall be set at time as per commissioning requirement.
Note: Tag number has been revised and the same is marked in yellow.
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