Maintenance & Troubleshooting Guide for BHELSCAN Flame Scanner system

Precautionary checks Ensure the power supply to the panel is 230 VAC. Ensure the Pico fuse rating is 120mA. In case if it is 60mA or less, replace it with 120mA Pico fuses. Ensure capacitors (4700 uF, 16 V) are present at pins 28-32 on the motherboard before energizing the elevation(ref Fig 2 & Fig 3). While the panel is in ON condition and elevation is energised, it is not advisable to remove and insert Flame processing cards although Hot Swapping is taken care in design. In case, if the cards are not inserted properly, ensure that the power supply to that elevation is OFF to reinsert the cards properly.

The BHELSCAN Amplifier and FSH Assembly are calibrated at our works and hence no calibration is required at site until any component replacement is done on Flame Scanner Head housing Electronics card. Minor tuning may be required only during the burner light up and it shall be limited to BHELSCAN Amplifier alone .

Erection and Commissioning

I. Flame Scanner Cable termination: Notes: 1. The flame scanner cable is special type triple shielded cable. The termination for three shields has to be done as per the drawing 3-95088-90784, Rev.0. 2. Please instruct the Cable laying & termination contractor to take care of the following precautions: 1. The FS cable entering the Panel end, needs to be taken upto to the terminals of BHELSCAN Amplifier Chassis without cutting the shield wires and removing the cable outer sheath at the gland plate on Panel bottom. The outer sheath shall be removed only for a length of for 6 to 9 inch from the cable end (from terminals of BHELSCAN Amplifier Chassis) for termination of wires and shield wires.

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3.

Before cable termination at both Panel and field ends, the FS Cable shall be checked to ensure: a. All the wires and shield wires of each corner cable is free from earth or ground. b. All the wires of each corner cable is not showing continuity with shield & other wire. After ensuring Action No. 3 and without any corner FS cable termination at both panel and field ends, the BHELSCAN Amplifier chassis shall be powered up. a. With the power switch in ON position, the Intensity display should show input open by flashing 100%. The channel fault light should be ON and the system fault light in 2/4 output module should be ON. b. Please observe for 5 minutes. If the indication is OK, then proceed further. After ensuring Action Nos. 3 & 4 above, the FS Cable of corner 1 shall be terminated at both panel and field ends after switching OFF the power for that elevation. a. Now the corner 1 fault light should be OFF. During furnace OFF condition, the display corresponding to corner 1 should show 00 to indicate the dark furnace condition. b. Please observe for 5 minutes. If no abnormal condition is observed, then proceed further. If no abnormal condition is observed, then proceed further by connecting FS Cables of corner 2, 3 and corner 4. Observe 5 minutes after each corner cable is terminated. After ensuring Action No. 6 above, proceed with other Commissioning activity.

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II. Flame Intensity, Frequency and AC Gain tunings 1) Pot settings (Ref Fig. 1):

Description RP1: AC gain pot (Coal) RP6: AC gain pot (oil)

Set value (k ohms) 120 - 140 80

Fig: 1 Flame Processor Card

Note: For setting AC gain, remove the flame processor card and adjust the pot to the required value. If it is not picking the coal flame, the AC gain pot (coal) can be suitably reduced upto 200 k ohms.

2) DIP Switches (Ref Fig. 1):

Description S1: Intensity Pull In (%) S2: Intensity Pull Out (%) S3: Coal freq. set value (Hz) S4: Oil freq. Set value (Hz)

Set value 40 30 5 20

Note: The above table shows recommended set values. However set values can be changed as per the process requirements. Set values also depend on the quality of coal and combustion. 3) DIP Switch setting method: Binary-Decimal Chart Binary Position Decimal Equivalent 8 2 128
7

7 2 64
6

6 2 32
5

5 2 16
4

4 2 8
3

3 2 4
2

2 2 2
1

1 2 1
0

The following example illustrates method of setting DIP switch. For example you want set for Intensity Pull out at 3 0 %. Split the decimal 30 into realizable binary combinations with ON/OFF at various positions as shown in the below table whose final sum results into required set value. Binary Position Decimal 8 ON 0 0 7 ON 0 0 Sum = 6 ON 0 0 30 5 OFF 2 16
4

4 OFF 2 8
3

3 OFF 2 4
2

2 OFF 2 2
1

1 ON 0 0

Note: OFF corresponds to 1 & ON corresponds to 0

III. Flame Scanners Intensity readings are low. In case the Flame Scanners Intensity reading is less than 40% even at full load of the boiler, assuming the flame inside the boiler furnace is good and the SA Dampers are maintaining Furnace to Windbox DP to corresponding load, ensuring proper combustion, the following points shall be checked: 1) Remove the Scanner Head Assemblies one by one and blow air through guide pipe assembly to flush and remove the settled coal dust obstructing the flame viewing. Clean the Flame Scanners the collimator lens & LBA lens if required. Ensure proper Scanner Cooling air is flowing through the FS Guide pipe assembly. By checking the following, otherwise the coal dust settled on the furnace side in front of the scanner detector tube may obstruct the flame viewing partially resulting in low intensity readings. a. b. c. d. e. f. 4) 5) Scanner fan speed whether running at rated speed. Scanner cooling air pressure at the fan outlet. Scanner cooling air pressure at scanner cooling air many fold. Scanner filter pluggage DP across the filter is normal i.e less than alarm level. Scanner filter pluggage DP switch output is connected to annunciation system. DP Switch functioning / calibration.

2) 3)

Ensure the calibration of Scanner Head Electronics as per the Calibration Procedure. Check for any fouling inside the scanner guide pipe. Ensure all the Flame scanner head Assemblies inserted inside the guide pipe assembly have reached the end position on the furnace side. This can be checked during the boiler shut down. Adjust the Fiber Optic Cable to reach fully inside the Lens Barrel Assembly for its correct position and lock the two check nuts. Without disturbing the scanner head electronics card (no tuning of SPAN and ZERO adjustment). Check Fiber Optic Cable condition by placing a light source at one side of fiber optic and observing at the other end of the fiber optic. The brightness to darkness spots shall not be less than 70:30.

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IV. Checking and tuning of Process Parameters 1) 2) Inspect physically the flame at corners inside the furnace. The flame is not healthy. Check and adjust the following: a. Heavy oil / Light oil / atomising steam / air parameters at headers and gun trips.

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c. d. e.

Check the SADC dampers positions. They should be as per the recommended positions. If SADC system is in auto mode of control, check whether it is as per the recommended parameter characteristics. Ensure closing of SADC dampers at the corners at elevations were fuel is not fired. Ensure physically at site whether damper positions are as per the indications displayed in the control desk or MMI in the control room. Using Bias arrangement ensure coal fuel air dampers are not opening beyond 40%.

3)

Check pulverized coal fineness and ensure it is at the required level. Course coal power in poor flicker frequency of the flame. The fineness of the coal should be >90 in 50 mesh and >70 in 200 mesh.

Note: Furnace to wind box DP is an important parameter to be maintained always.

Fig2: Hot swapping capacitors

Fig3: Hot swapping capacitors

Calibration Procedure
The scanner head electronics are calibrated after manufacturing at vendor works. If a component on the electronics card is replaced, field adjustment of the gain and offset potentiometers and dark furnace bias will be required. Calibration of Scanner Head Electronics: Turn the power supply OFF. Remove the Flame scanner head assembly from its guide pipe. Disconnect the cable and open the head assembly for access to the scanner head electronics card. Equipments required for calibration: a. Digital voltmeter (DVM) b. 1 mA dc current source (1 V dc in series with a resistor; 1k, 1/8W, 1%) c. 1 A dc current source (1V dc in series with a resistor; 1M, 1/8W, 1%) d. A light (100w bulb) source. Calibration is carried out in two steps. Gain and Offset Adjustment Dark Furnace Bias Adjustment

Gain and Offset Adjustment

In gain and offset adjustment we are tuning the log amplifier to behave as per the I/O characteristics. The log amplifier output voltage varies from >6.4 V to 0 V for input currents of <1nA to 1mA respectively. By providing input currents of 1 A and 1mA the output at pin 10 of log amplifier IC should be 3V and 0V respectively as per the characteristics curve. Simultaneously output between terminals C and D should be 1V and 0V. To ensure the above conditions connect the 1 A current source to the photo diode positive lead terminal which is in turn connected to the input pin (2) of log amplifier IC. Switch on the power supply for scanner head electronics card and measure the output at pin 10 of log amplifier, which should be 3V and output between terminals C & D should be 1V. If the output is not 1V, adjust the pot R103 until the required output is obtained. Now connect the 1mA current source to the photo diode positive lead terminal which is in turn connected to the input pin (2) of log amplifier IC. Switch on the power supply for scanner head electronics card. The output measured at pin 10 of log amplifier and between terminals C & D should be 0V. If the output is not 0V, adjust the pot R101 until the required output is obtained. Disconnect the current source to proceed further for dark furnace bias adjustment.

Dark Furnace Bias Adjustment

Completely block the light entering fiber-optic cable and open the scanner housing. Connect the pigtail cable to head assemble and switch on the power supply for scanner head electronics card Connect a digital voltmeter (DVM) between the signal C and common D terminals on the electronics card. The output voltage should be 2.1V. If the output is not obtained tune pot R113 to get the required output. Work under a dark cloth to reduce the amount of ambient light admitted to the scanner head. Now place the lens barrel assembly in front of the light source (100w bulb) and measure the output between C & D. The output voltage will be in the range of 0.7 to 0.9V. This completes the scanner head electronics adjustments. Disconnect the test leads, reassemble the scanner assembly and insert it in the guide pipe. All four scanner channels, under dark furnace conditions, should have a similar intensity meter reading.