Furnace Safeguard Supervisory System

K.C. Yadav, AVP,

Noida Technical Training Centre
 Learning Agenda
» Objective of FSSS
» Inter facing of field equipments and
instrumentation
» Operational features of FSSS
» Role of FSSS in starting/shutdown
» Role of FSSS in maintaining the
design prescribed values of the
parameters
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It must be recognized that no amount of
written instruction can replace intelligent
thinking and reasoning on the part of boiler
operators, especially when coping with
unforeseen operating conditions. It is
operators’ responsibility to become
thoroughly familiar, not only with immediate
steam generating equipment but also with all
pertinent control equipment. Satisfactory
performance and safety depend to a great
extent on proper functioning of controls and
auxiliary equipment.
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 Purpose
The FSSS is designed to ensure the
execution of safe, orderly operating
sequence in the start up and shutdown of
fuel firing equipment and to prevent errors
of omission and commission in following
such a safe operating procedure.

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 Purpose
 Furnace purge supervision.
 Secondary air damper modulation, on/off control
and supervision.
 Light oil on-off control and supervision.
 Heavy oil on-off control and supervision.
 Pulveriser and feeder on-off control and
supervision.
 Flame scanner intelligence and checking.
 Overall boiler flame failure protection.
 Boiler trip protection.
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 Purpose
 Prevent any fuel firing unless a satisfactory furnace
purge sequence has first been completed.
 Prevent start-up of individual fuel firing equipment
unless certain permissive, interlocks have been
satisfied.
 Monitor and control proper component sequencing
during start-up and shut-down of fuel firing
equipment.
 Subject continued operation of fuel firing equipment
to ascertain safety interlocks remaining satisfied.
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 Purpose
 Provide component status feedback to the
operator and, in some cases, to the unit control
system and / or to the data logger.
 Provide flame supervision when fuel firing
equipment is in service and effect an Elevation
Fuel Trip or Master Fuel Trip upon certain
condition of unacceptable firing / load
combination.
 Effect a Master Fuel Trip upon certain adverse
Unit operating conditions.
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 Subsystem of FSSS
 Purge Permissive (s)
 HOTV Open/Close Interlocks
 HORV Open/Close Interlocks
 Oil Guns Start/Stop Cycle
 Boiler Protection Logics
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 Subsystem of FSSS (Cont.)
 PA Fan Interlocks
 Coal Mill Start/Stop Interlocks
 Coal Feeder Start/Stop Interlocks
 Scanner Air Fans
 Seal Air Fans
 Secondary Air Damper Interlocks
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 Purge Permissives
 All HFO Nozzle Valves Closed
 HFO Trip Valve closed
 No Boiler Trip From MFR A & B
 All Pulverizers Off.
 All Feeders Off
 All Flame Scanners Sense No Flame
 Both PA fans Off
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 Purge Permissives (Cont.)
 All Auxiliary Air Dampers Modulating and
furnace to wind box P OK
 All Hot Air Gates Closed
 Air Flow > 30 %
 Mode Permit Proven (Air Flow < 40%
 Burner Tilt Horizontal)
 Drum Level Satisfactory
 FSSS AC / DC Power Available.
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 HOTV Interlocks
To Open HOTV : Permissives
SET I
 No. Boiler Trip persisting

HFO Header temperature satisfactory >950 C

HFO supply pressure > 15 Kg / cm2
 All HONV’s closed
 No close / Trip command
 Open PB depressed
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 HOTV Interlocks
To Open HOTV : Permissives
SET II
 All HONV’s closed
 MFT acted
 HORV open
 Open PB depressed

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 HOTV Interlocks
1. HOTV closes automatically under the following conditions:

Any HONV not closed AND

a) HFO pressure low < 3 Kg/cm2 OR

b) Atomizing steam pressure low < 3.5 Kg/cm2 OR
c) HFO Header Temperature Lo-Lo for > 2 secs. < 95 0C

2. Any HONV not closed and MFT acted

3. Loss of critical power > 2 Seconds

4. HOTV can be closed manually confidentia

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 HORV Interlocks
 HORV can be opened by pressing the OPEN Push

button (PB) from Console if All the HONV s are

closed.

 HORV closes automatically when any HONV is not

closed OR by pressing close PB.

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 FROM AUXILIARY
HFO Supply Scheme STEAM HEADER

HFO PUMP-1

HFO
s HTR-1 s

HFO PUMP-2
TO BOILER
HFO FRONT
s HTR-2 s
FROM HFO
DAY TANK

HFO PUMP-3

HFO
s
s
HTR-3

TO HFO
DAY TANK
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 HFO Scheme At Boiler Front
HOTV HOFCV

FT

AB ELEVATION

CD ELEVATION
M

SHORT FT EF ELEVATION
RECIRCULATION

HORV

HFO HFO
SUPPLY RETURN
LINE LINE

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Atomizing Steam Scheme AB ELEVATION

CD ELEVATION

EF ELEVATION

Oil Gun Connection

HFO NOZZLE
VALVE SCAVENGE OIL GUN
VALVE

ATOMISING
STEAM VALVE
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 Pair Firing Mode (Start Up)
 Pair firing mode is selected when no feeder is in
service. Pairs are made for the opposite corners.
(Pair 1-3 and Pair 2-4)
 When pair 1-3 start push button is pressed;
A 30 second counting period is started
A 70 second counting period is started
 Oil Gun No-1 advances from retracted position if, it
is engaged, corresponding scavenge valve is
closed, atomizing steam and HFO isolation valves
are open.
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 Pair Firing Mode (Start Up)
 HEA igniter advances.
 Atomizing steam valve opens.
 Igniter starts sparking.
 HFO Nozzle valve for corner 1 opens
 HFO catches fire and flame indication comes.
 After 25 seconds igniter retracts.
 When the 30 second counting period expires
command will go to corner 3 and same events will
take place.
 Corner 2-4 can also be placed exactly in the same
manner.
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 Elevation Firing Mode (Start Up)
 Elevation firing mode is selected when any feeder is
proven.
 Oil elevation is placed in service when Pair 1-3 or Pair 2-4
start Push Button is pressed. In elevation firing mode also
the oil guns are proven on pair basis.
 First command goes for placing Pair 1-3 into service and
Pair 1-3 is placed into service exactly in the same way as
in the pair mode.
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 Elevation Firing Mode (Start Up)
 First start command goes to corner-1 then after 30 second
start command goes to corner-3.
 After the start command has gone to corner 3, a 30 second
counting period is started. When 30 seconds counting
period expires then start command goes for corner 2-4 and
corner 2-4 are placed into service exactly in the same
manner as in the pair mode.

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 PAIR FIRING MODE (SHUT DOWN)
 Pair firing mode is selected when no feeder
is in service. Pairs are made for the opposite
corners. (Pair 1-3 and Pair 2-4)
 When pair 1-3 stop push button is pressed
the following events take place
A 30 second counting period is started
A 340 second counting period is started
 Oil Gun No-1 HFO nozzle valve closes.
 Scavenge and atomizing steam valve opens.
 HEA igniter advances and spark remains for
15 seconds.
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 Pair Firing Mode (Shut Down)
 When atomizing steam valve is proven fully open,
a 5 minutes counting period starts.
 When 5 minutes counting period expires scavenge
valve and atomizing steam valve closes and
further closing command goes HFO nozzle valves
to reinsure that they are fully closed.
 Oil Gun corner no-1 retracts to its home position.
 When the 30 second counting period expires stop
command will go to corner 3 and same events will
take place.
 Corner 2-4 can be shut-down exactly in the same
manner.
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 Elevation Firing Mode (Shutdown)
 Elevation firing mode is selected when any feeder is proven.
 By pressing stop push-button of Pair 1-3 or Pair 2-4 the
following events will take place.
 Corner 1-3 will be shut-down in the similar way as in the pair
mode.
 When stop command has gone to corner 3, a 30 second
counting period is started.
 When 30 seconds counting period expires then stop
command goes for corner 2-4 and corner 2-4 are shut-down
exactly in the same manner as in the pair mod
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 Boiler Trip Conditions
 Both FD Fans Off
 All ID Fans Off
 Inadequate Water Wall Circulation
 Loss Of Reheater Protection
 Deaerator level Lo-Lo ( -2134 mm 2 / 3 logic)
 All Boiler Feed Pumps Off
 Drum Level High-High (> + 250 mm, delay of 10 seconds)
 Drum Level Lo-Lo (< - 375 mm, delay 10 seconds)
 Elevation Power Failure For > 2 seconds.
 Furnace Pressure High-High (> + 325 mmWCl, 2 / 3 logic)
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 Boiler Trip Conditions
 Furnace Pressure Lo-Lo (< -250 mmWC, 2 / 3 logic)
 Loss Of All Fuel
 Unit Flame Failure
 Loss Of Critical Power For > 2 seconds
 Loss Of 220 V DC For > 2 seconds
 Loss Of ACS Power > 2 seconds
 Simulated Trip
 Air Flow < 30 %
 Both Emergency Push Buttons Pressed. confidentia
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 Boiler Trip
When the boiler trips the following events takes place
 Boiler trip red lamp comes on.
 MFT A & B trip lamp comes on and reset lamp goes off.
 Cause of trip memory can not be reset till the furnace
purge is completed.
 F D Fans Control is transferred to manual.
 I D fans vane position is transferred to manual.
 Pulverizers are tripped.
 Coal feeders are tripped.
 P A fans are tripped.

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 Boiler Trip (Cont.)
When the boiler trips …….
 Cold air dampers opens 100 %.
 HFO trip valve closes.
 All HFO Nozzle valves closes.
 Upper and Lower Fuel air damper opens.
 Auxiliary air damper opens and control is transferred to
manual.
 Loss of all fuel trip protection disarms.
 S/H and R/H spray block valves S-82 & R-31 closes and
can not be opened unless furnace purge is completed.
 Turbine Trips
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Inadequate Water Wall Circulation

1. Boiler load > 60 % and less than two pumps or

pump on and differential pressure < 10 psi.

2. Boiler load < 60 % and no BCW pump on or

pump on and differential pressure < 10 psi.

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 Reheat Protection
1. Turbine trip or generator circuit breaker open and hp/lp

bypass opening < 2 %.

2. Turbine working (hp & ip cvs opening > 2 % and load

shedding relay operated and hp/lp bypass opening < 2 %.

3. Turbine not working and boiler working and hp/lp bypass

opening < 2 %.

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 MFT 5 SEC RESET
Loss of all fuel arming
SET
Any elevation
¾ Nozzle valve proven
All HFO Elevation Trip

All feeders off 2 SEC

All HFO Nozzle

valve closed Loss of all
HOTV NOT OPEN fuel trip
2 SEC
All feeders off

Loss of All Fuel Trip

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Any Feeder Proven 2 Sec

Elevation GH No Flame Vote

Elevation FG No Flame Vote

Flame
Elevation DE No Flame Vote
Failure
Trip
Elevation BC No Flame Vote

Elevation AB No Flame Vote

Flame Failure Trip

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 Flame Failure Vote Logics
Elevation DE Scanners No Flame
Feeder E Off
Elevation DE
No Flame Vote
Feeder D Off 2 Sec

Elevation BC Scanners No Flame

Feeder C Off
Elevation BC
Feeder B Off No Flame Vote
2 Sec
Elevation AB Any HFO
Nozzle Valve Not Closed

Elevation AB 2/4
Nozzle Valve Not Proven

Elevation AB Elevation AB
Scanners No Flame
No Flame Vote

Feeder A Off
2 Sec

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ELEVATION GH ANY HFO
Flame Failure Vote Logics
NOZZLE VALVE NOT CLOSED

ELEVATION GH 2/4
NOZZLE VALVE NOT PROVEN

ELEVATION GH
SCANNERS NO FLAME
ELEVATION GH
NO FLAME VOTE
FEEDER H OFF

2 SEC

ELEVATION FG SCANNERS NO FLAME

FEEDER G OFF
ELEVATION FG
NO FLAME VOTE
FEEDER F OFF

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 Mill Interlocks
Start Permissive (s):
Mill starts after the ‘ON’ push button is pressed if
following
conditions are fulfilled.
Pulveriser Ready available signal will be available if
following conditions are fulfilled
 M.D.V. is open (all four)
 Mill outlet temp < 93 0 C
 Feeder local switch in Remote
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 Mill Interlocks
 Pulverizer start permit (if Nozzle tilt Horizontal & air
flow < 40 %) OR
Any feeder proven & NO MFT Tramp iron valve open
 Cold air gate open
 Feeder inlet gate open
 Lub oil level & temp. adequate
 Lub oil pressure not low for more than 300 sec
 No Mill trip existing

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 Mill Interlocks
P.A. permit available.
(i) Hot P.A. duct Pressure. not low (< 625 mmWCl)
(ii) P.A. duct pr. not lo-lo ( > 500 mmWCl AND
(iii) Both FD s ON and both PA fans ‘ON’ or (Any PA fan
ON and any FD Fan ‘ON’ and > 4 mills not ON)
 No Auto pulverizer unsuccessful start
 Seal air Header to mill under bowl DP satisfactory > 8" WCl
 Mill not ‘ON’
 Pulverizer Ignition permit available.

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 Mill Interlocks
FOR Mill A
 AB elevation 3/4 HONV’s open
OR
 Boiler load > 30 % and Feeder - B speed > 50 % ( > 30 T/hr.)
For Mill B
 AB elevation proven 3/4 HONV’s open
OR
 Boiler load > 30 % and Feeder A or Feeder C proven.

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 Mill Interlocks
For Mill C
 CD elevation proven OR
 AB oil elevation and feeder B proven OR
 Boiler load > 30 % & either feeder B or Feeder D proven

For Mill D
 CD elevation proven OR
Boiler load > 30 % and either feeder C or feeder E proven.

For Mill E,F,G & H identical logic

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 Pulveriser Trip Conditions
 Auto / manual mode selected to manual & stop PB
depressed.
 Pulv. start command given & not ‘ON’ for > 2 Secs.
 Loss of Elevation OR Unit Power for > 2 Secs
 Pulv ‘ON’ & seal air / under DP Low > 1 min < 5”wc
 Pulv ‘ON’ and lub oil pump OFF > 10 sec.
 Pulv ‘ON’ and lub oil pr. low > 10 secs. < 1.76 Kg/cm2
 Ignition permit required (> 180 secs) & ignition permit
lost (i.e. within 180 sec of feeder start)
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 Pulveriser Trip Conditions
 Any of the MDV is not fully open
 Hot PA duct. pr. Lo < 625 mm of WCL (delay 5 sec)
 Hot PA duct. pr. Lo - Lo = < 525mm WC (instantaneous)
 MFT
 PA / FD Fan trip
a) If both PA Fans & both FD fans running & any PA or any FD
Fan trips then mills start tripping from top elevations with 2 secs
time delay till 4 mills are available.
b) If both PA / FD fans trip then all mills will trip.

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Pulverizer Seal Air Valves Interlocks
 Valve opens when Pulverizer start command is given
OR Millis ON
 Valve closes when Pulverizer is OFF

Hot Air Gate Interlocks

 Hot air gate (HAG) opens when Pulverizer is ‘ON’ AND
Hot air gate open
 P.B. depressed or auto HAG open command is there
AND NO HAG close command.

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Hot air gate closes when
1. Loss of power > 2 secs
2. Pulverizer off
3. Pulverizer outlet temp > 93 0 C
4. Close P.B. depressed
5. Feeder Trips.(Delay 40 sec)
6. Auto pulverizer unsuccessful start
7. Auto pulverizer run feeder speed to minimum
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 Feeder Start Permissive (s)
 Pulveriser Ready is available
 Feeder speed demand at minimum
 Pulveriser manual mode
 Pulveriser ignition permit available
 No feeder stop command
 No MFT
 Pulveriser ‘ON’
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 Feeder Trip Condition
 Ignition energy removed within 180 seconds of
feeder start
 Feeder in manual mode & stop PB depressed
 Auto Pulverizer Feeder stop command
 Pulverizer OFF
 MFT
 No coal on belt Discharge plugged
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 SADC
The secondary air dampers located in wind box
apportions the total secondary air between
various elevations. How this air is proportioned,
depends on which fuel is being burnt, the
number of elevations in service and the firing
rate at each elevation.
The function of Secondary Air Damper
Control System (SADC) is to proportion the
total secondary air around the firing elevation as
per the criteria spelt above. In fact the SADC
system is a combination of both analog and
digital system, as the amount of fuel fired and
the no. of firing elevations decide the damper
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The auxiliary air dampers are positioned to
maintain the required wind box to furnace
differential pressure according to the boiler load. In
the initial periods of operation, the flame condition
with reference to ignition stability, ignition point
relative to fuel nozzles, overall combustion
conditions in the furnace are to be studied for
various wind box to furnace differential pressures
and the values are to be optimized at site (the
values are adjustable). Based on this, the final
curve showing the relationship between the wind
box to furnace differential pressure versus the
boiler load is to be decided for the type of coal
used.

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The auxiliary elevation dampers act as fuel (oil) air
dampers when oil firing is taking place and is open
to a preset position. The fuel (oil) elevation
dampers are selected to be closed if there is a
back up trip in that elevation and adjacent
pulverizers are off and “No Boiler Trip” signal is
present. When a HFO Elevation is started (i.e.
when the associated “elevation back-up” trip is
removed) the associated auxiliary air dampers in
that elevation are set to preset position for HFO
firing.

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Above 30% MCR boiler load, the auxiliary air
elevation associated with the main fuel elevation in
service modulate to maintain the varying DP.
Those not associated with any elevation in service
are closed from top to bottom. The closing signal
comes from FSSS.
When the unit load is increased above 30% MCR,
the Aux. air dampers of elev. AA,AB, BC, CD, DE,
EF & FF are closed in a timed sequence (10 sec.
interval) provided the associated coal elevations
are not in service and the associated oil elevations
are not in service. The auxiliary air dampers are
closed, starting from the top elevation, progressing
towards the lowest elevation.
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 All elevations of the aux. air dampers will be automatically
switched to “Manual” control and then commanded to open
100%, if any one of the following conditions exist.
 Both FD fans are OFF.
 Both ID fans are OFF.
 Master fuel trip occurs.
 Loss of unit critical power . (+24V DC)
Also the auxiliary air control loop is tripped to manual if any
of the following conditions exist.
 DP transmitter deviation high.
 Failure of selected DP transmitter
 Furnace to Windbox DP very high (> 240mm WCL).

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The fuel air damper control system positions the
fuel air damper in proportion to the fuel firing rate.
In the initial periods of operation, the flame
condition with reference to ignition stability, ignition
point relative to fuel nozzles, overall combustion
conditions in the furnace are to be studied for
various fuel air damper positions and the values
are to be optimized at site.
Based on this the final curve showing the
relationship between the fuel air damper positions
versus the fuel feed rate is to be decided for the
type of coal used.
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 All elevations of fuel air dampers are
commanded to open 100% when any
one of the following conditions exist.
 Both FD fans are OFF.

 Both ID fans are OFF.

 Master fuel trip occurs.

 Loss of unit Critical Power.(+24 VDC)

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On coal fired boilers the characteristics of
fuel like, Fixed Carbon, Volatile Matter
and Ash composition will determine the
optimum wind box to furnace differential
pressures and the fuel air damper
positions. Accordingly the optimized
settings are to be decided as above for
the coal used.

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Later, if the coal quality changes or
the coal source itself is changed, it
shall be necessary to once again
carryout optimization studies for the
new coal and revised settings are to
be finalized.

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Modulation of Auxiliary Air Dampers

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Modulation of Fuel Air Dampers

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Modulation of Over Firing Air Dampers

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 The two elevations of the over fire air dampers will be
automatically switched to “Manual” control and then
commanded to open 100%, if any one of the following
conditions exist

 Master fuel trip occurs.

 Loss of unit critical power .(+24 VDC)
 Both FD fans are OFF.
 Both ID fans are OFF.
 WB To Furnace DP exceeds 240mm WCL.

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Thank you
12th July, 2008