Boiler Interlock And

Protection
Manish Dhruw
Asst Manager
14843
Cpp-540

Boiler interlock and

protection

Boiler Interlock - A Boiler Interlock is an

arrangement of heating controls. It ensures the boiler
does not fire when there is no demand for heat.
Protection of boiler Boiler protection are provide
to detect the abnormal condition by constantly
measuring the various parameter under normal and
faulty condition. If any abnormality happened trip
the boiler to prevent from major damage.
Need

To
To
To
To

of Interlocks & Protection

avoid
avoid
avoid
avoid

operational faults
equipments damage.
accidents to individuals.
system disturbances

In case of
MFT Trip
Master Fuel Trip - it produces trip signal for fuel
systems from operation , then trip the boiler out of
service away from danger. this relay needs many
will failure.
be found
9. Unit flame
conditions
1. Both ID to
fanoperate
trip. , these conditions
at the following points.
10. Loss of fuel.
2. Both FD fans trip.
11. Loss of scanner
3. Emergency manual
cooling air (Scanner air
trip.
pressure<2 KPa with 5
4. Turbine tripped and
min time delay).
HPLP bypass not
12. Both APH tripped.
opened (RH protection
13. Oil burner light off
act).
5. Drum level low low
failed.
low (<-325mm with 5

sec delay).
Other than MFT 6. Total air flow<30%.
1. MS

Boiler

Interlocks cum protections

1. If one ID fan trips, one FD fan will trip in the same sequence.
2. If one FD fan trips, one ID fan will trip in the same sequence.
3. If one APH trips, one ID fan, one FD fan and one PA fan will trip in
the same sequence.
4. In case of GCB opening, top elevation mill or non adjacent mill
will trip.
5. If drum level200 mm, EBD will open.
6. If drum level150 mm, EBD will close.
7. Feed water flow<50 TPH, Economiser recirculation MOV will
open.
8. Feed water flow>80 TPH, Economiser recirculation MOV will
close.
9. If superheated steam pressure is higher than 14.86 MPa ERV will
open and if pressure is lower than the value ERV will close (if kept
in service).

Other
Protections
1. Boiler drum pressurea) Higher than 17.24 MPa LHS safety valve will lift
and it will reset @ 16.35 MPa.
b) Higher than 16.74 MPa RHS safety valve will lift
and it will reset @ 16.21 MPa.
2. Superheated steam pressurea) Higher than 15.29 MPa, LHS safety valve will lift
and it will reset @ 14.765 MPa.
b) Higher than 15.2 MPa, RHS safety valve will lift
and it will reset @ 14.747 MPa.
3. CRH steam pressurea) Higher than 3.058 MPa, LHS safety valve will lift
and it will reset @ 2.947 MPa.
b) Higher than 2.963 MPa, RHS safety valve will lift

Alarm

Drum level
1. Level>125 mm: high
priority alarm.
2. Level>-125 mm: high
priority alarm.
3. Level>250 mm:
emergency priority alarm.
4. Level>-250 mm:
emergency priority alarm.
Furnace pressure
1. Pressure>30 mm of
H2O: high priority alarm.
2. Pressure>-30 mm of
H2O: high priority alarm.
3. Pressure>50 mm of
H2O: emergency priority
alarm.
4. Pressure>-50 mm of

MS & RH Temperature
1. MS temperature>5450C:
high priority alarm.
2. MS temperature>5500C:
emergency priority alarm.
3. RH temperature>5450C:
high priority alarm.
4. RH temperature>5500C:
emergency priority alarm.
Others
1. APH flue gas inlet
temperature<3000C: high
priority alarm.
2. O2<1: high priority
alarm.
3. O2 zero: emergency
priority alarm.
4. Furnace DP90 mm of

ID Fan interlock &

protection

1. No ID fan A/B converter/ device fault.

2. No ID fan protection acted.
AND
3. ID fan A/B inlet & outlet damper
closed.
4. ID fan IGV in minimum position.
5. APH A/B flue gas inlet & outlet damper
open.
6. APH A/B running
1. ID fan A/B breaker protection acted.
Or
OR
2. BMS trip ID fan A/B. Or
3. FD fan A/B tripped. Or
4. APH A/B tripped. Or
5. ID fan A/B temperature protection

e
Interl
ock:

TRIP
enabl
e
Interl
ock:

ALARM
1. Fan/ motor bearing temperature750C: high
priority alarm.
2. Fan/ motor bearing temperature800C:
emergency priority alarm.
3. Fan bearing vibration6.3 mm/sec: high
priority alarm.
4. Fan bearing vibration11mm/sec:
emergency priority alarm.
5. Motor winding temperature1100C: high
priority alarm.
6. Motor winding temperature1200C:
emergency priority alarm
TRIP
1. Motor winding temperature1300C (2 out of
6 temperatures with 60sec time delay).
2. Fan/ motor bearing temperature900C (with
60 sec time delay).

FD Fan interlock & protection

1. No FD fan A/B converter/ device fault.

2. No FD fan protection acted.
Start
3. FD fan A/B outlet damper closed.
enable
4. FD fan IGV in minimum position.
5. APH A/B flue gas inlet & outlet
damperInterlo
AN
ck:
open.
D
6. APH A/B running.
7. ID fan A/B running.
1. FD fan A/B breaker protection acted.
Or
2. BMS trip FD fan A/B. Or
3. ID fan A/B tripped. Or
OR
4. APH A/B tripped. Or
5. FD fan A/B temperature protection

TRIP
enable
Interlo
ck:

ALARM
1. Fan/ motor bearing temperature750C: high
priority alarm.
2. Fan/ motor bearing temperature800C: emergency
priority alarm.
3. Fan bearing vibration6.3 mm/sec: high priority
alarm.
4. Fan bearing vibration11mm/sec: emergency
priority alarm.
5. Motor winding temperature1100C: high priority
alarm.
6. Motor winding temperature1200C: emergency
priority alarm.
TRIP
1. Motor winding temperature1300C (2 out of 6
temperatures with 60sec time delay).
2. Fan/ motor bearing temperature900C with 60 sec

PA Fan interlock &

protection

1. No PA fan A/B converter/ device fault.

2. No PA fan protection acted.
3. PA fan A/B outlet damper closed.
AND
4. PA fan IGV in minimum position.
5. APH A/B flue gas inlet & outlet
damper open.
6. APH A/B running.
7. ID fan A/B running.
8. FD fan A/B running.
9. No boiler trip command.
1. PA fan A/B breaker protection acted.
Or
2. MFT trip PA fan A/B. Or

3. ID fan A/B tripped. Or

4. FD A/B tripped. Or
5. PA fan A/B temperature protection
acted.

OR

Interl
ock

Trip
enabl
e
Interl
ock:

ALARM
1. Fan/ motor bearing temperature75 0C: high priority alarm.
2. Fan/ motor bearing temperature80 0C: emergency priority
alarm.
3. Fan bearing vibration6.3 mm/sec: high priority alarm.
4. Fan bearing vibration11mm/sec: emergency priority alarm.
5. Motor winding temperature110 0C: high priority alarm.
6. Motor winding temperature120 0C: emergency priority alarm.

TRIP
1. Motor winding temperature130 0C (2 out of 6 temperatures
with 60 sec time delay).
2. Fan/ motor bearing temperature90 0C with 60 sec time delay.
3. Fan bearing vibration11mm/sec with 60 sec time delay.
4. PA fan motor protection (over current, earth fault, negative
sequence, phase fault etc) acted.
5. MFT trip PA fan.
6. ID fan/ FD fan A/B trip to PA fan A/B trip.
7. PA fan running and fan discharge damper closed.

Seal air fan interlock

& protection

1. No fan converter/ device/ breaker

fault.
2. Any one PA fan running.
3. Fan IGV in minimum position.
4. In case of one fan running & other
fan standbya) If running fan getting tripped
due to any protection acting then
stand by fan will start in interlock if
selected.
b) If seal air pressure becomes low
(<6 KPa), then standby fan will start
by interlock.
4. During unit start up fan start
enable will come with the start of
any PA fan if selected in fan auto
start interlock.
**Command will go to Seal air fan
IGV for 60% opening in auto with

e
interl
ock:

AND

OR

1. Seal air fan current>200

Amp:
high priority alarm.
2. Seal air fan current>260
Amp: emergency priority
alarm.
3. Seal air discharge
pressure<800: high priority
alarm.
4. Seal air discharge
pressure<600: emergency
priority alarm.
1. Seal air fan current
284Amp.
2. Both PA fans stopped/
tripped (fan trip after 2Sec).

ALARM

TRIP

Scanner Air Fan Interlock

Protection

1.
No
motor
or
breaker
protection acted.
2. Fan is in remote.
3. In case of one fan is running
and the other is in stopped
conditiona) By interlock input if one fan
is stopped/ tripped, standby fan
will start in auto.
b) If scanner air header
pressure<2 KPa for 5 sec, then
standby fan will start in auto by
interlock input.
1. Scanner air header pressure<
low switch acting: emergency

AND

Start
Enable
Interlo
ck

Alarm

Trip

Mill Interlock &

Protection

1. No breaker/ motor
protection acted.
2. Lube oil pressure normal
for > 5 minutes.
3. No MFT acted.
AND
4. Boiler drum pressure>3.4
kg/cm2.
5. Secondary air
temperature>1770C.
6. Total air flow<40%
(230TPH).
7. MDVs are open.
8. Mill outlet
temperature<1150C.

Start
Enable
Interlock

1. Feeder trip and no mill

ignition permit.
2. MFT.
3. MDVs closed.
4. Lube oil pressure low (2 out of
3 lube oil pressure<low switch
act).
5. Seal air differential pressure
low low.
6. Loss of primary air
(differential pressure between
APH outlet primary air and
furnace pressure less than
460mm of H2O.
Other Interlocks:
1. On tripping of mill Close

AND

1. Mill lube/ hydraulic oil tank

temperature>750C: high priority alarm.
2. Mill lube oil thrust pad oil
temperature>600C: high priority alarm.
3. Mill lube oil thrust pad oil
temperature>700C: emergency priority
alarm.
4. Mill motor front/ rear bearing
temperature>750C: high priority alarm.
4. Mill motor winding
temperature>1000C: high priority
alarm.
5. Mill outlet, roller bearing
temperature>900C: high priority alarm.
6. Mill current>60 amp: high priority
alarm.
7. Mill inlet PA flow< 50 TPH: high

Alarm

1. Mill motor protection (over current,

earth fault, negative sequence, phase
fault etc) acted.
2. MFT trip mills.
3. MDVs closed trip mill (2 out of 4
MDVs).
4. Mill lube oil pressure low (2 out of
lube oil pressure<low switch acting)
trip mill.
5. Loss of primary air (differential
pressure between APH outlet primary
air and furnace pressure less than
460mm of H2O).
6. Feeder trip and no mill ignition
permit.
7. Seal air differential pressure low
low.

Trip

Coal Feeder Interlock &

Protection

Start enable Interlock:

1. No breaker or motor
protection acted.
2. Respective mill ignition
permit.
3. Feeder speed (VFD
command) minimum.
4. No mill trip command.
5. Feeder is in remote.

Start
Enable

AN
D

1.
2.
3.
4.

Mill trip/ emergency stop.

MFT.
Feeder running and no coal.
Mill outlet

OR

Interlo
ck

Stop/Trip
Enable
Interlo
ck:

1. Belt deviation of feeder switch

act: high priority alarm.
2. No coal switch act: high priority
alarm.
3. Coal jam switch act: low priority
alarm.
4. Feeder cleaner motor fault: low
priority alarm.
5. Coal flow zero: low priority alarm.

Alar
m

Trip

1. Mill trip to feeder trip.

2. MFT to feeder trip.
3. Feeder motor/ breaker protection
acted.

Mill Lub Oil Pump Interlock &

Protection

1. No breaker or motor
protection acted.
2. LOP is in remote.
3. Oil pool temperature of lube
oil>600C.

1. Oil pool temperature of lube

oil<450C.
2. After LOP starting if oil pool
temperature of lube oil<450C
and mill not running (30 mins
time delay).
3. After mill stopping after 4 hrs
time delay stop command will
go for LOP.

Start
enable
Interlo
ck

AND

OR

Stop/tri
p
enable
Interlo
ck

1. Lube oil pump stopped:

emergency priority alarm.
2. Lube oil pressure<low switch
act: emergency priority alarm.
3. Oil pool temperature>: 750C
high priority alarm.
4.
Lube oil thrust liner sump
temperature>: 600C high priority
alarm.
5. Lube oil thrust liner sump
temperature>: 700C emergency
priority alarm.
1. LOP motor/ breaker protection
acted.
2. Oil pool temperature of lube
0

Ala
rm

Trip

APH Interlock & Protection

1. No breaker or motor protection acted.

2. APH is in remote.
3. Guide and support bearing oil pump
running for minimum of 300 sec (for
U#2 APH).

AND

Interl
ock

Stop/tr
ip
enabl
e
Interl
ock:

1. APH flue gas inlet temperature<800C

OR
and fans (ID, FD & PA) are running.
2. For APH auxiliary motor, with the start
of APH main motor trip command will
Other
Interlocks:
go.
1. Start command will go for APH auxiliary motor (DC) with
the tripping of APH main motor.
2. In case of APH main motor VFD getting bypassed due to
any fault, APH main motor DOL supply will pick up.
3. For U#2 APHa) If APH support/guide bearing temperature> 54 0C, lube oil
pump will start.

a
h
T s
nk