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20th October 2014 furnace Safeguard Supervisory System

(FSSS)

This Post enumerates the conceptual, functional and design features of the
Furnace Safeguard Supervisory System supported by the physical arrangement
of this system in detail. The underlying idea is to create an awareness of this
system in its entirety.

Basic Concept of operation of FSSS

FSSS, as a contrast to combustion control, is an independent and discreet digital logic
system specially meant for safety and protection during starting, shut down, low load
and emergency conditions. It does not take part in the regular station operation as in
the case with combustion control which sends out continuous analogue signal to
maintain combustion rate at optimum value to match the demand of the boiler.
In the present BHEL designed boilers tangential ring system has been adopted. in
which air and fuel are admitted on elevation basis located at the corners of the furnace
and arranged to re tangentially at the centre of the furnace. Ignitors are provided at
appropriate locations to re directly across the line of admission of the oil stream.
Optical ame scanners are strategically located at different levels. Fuel air and auxiliary
air dampers are continuously modulated to distribute the incoming air for optimum ring
conditions. Wide angle ame scanners monitor the ame in the furnace as single entity.

Functions of FSSS

The furnace safeguard supervisory system has been designed to provide increased
safety, reliability, exibility and overall performance of the Boiler. This consists of the
following:
a) Furnace Purge Supervision: Which has interlocks for scanners purge airow,
drum level and all fuel.
b) Secondary air damper control: To automatically maintain wind box furnace
differential, regulate air to the fuel compartment and control the secondary air
dampers.
c) Ignitor control supervision : Which has interlocks for ignitor ame, furnace purge,
ignition fuel pressure and ignitor tip valve pos ition.
d) Heavy Oil Control and Supervision: Which has remote and manual start/stop. It
includes interlocks for heavy oil pressure and temperature, oil gun valve
positions, ignitor energy atomising differential and Iqcal maintenance switches.
e) Mill and Feed control and Supervision: Which has automatic operation from a
single operator start-stop switch for each mill. Individual switches are also
provided for the operator to control each mill. It also includes interlocks for
ignition energy, primary air-shut off gate position, mill outlet temperature and
proper mill start-stop procedure.
f) Flame scanners intelligence and checking: Includes automatic checking of each
scanner, scanner couting networks and scanner cabinet.
g) Overall boiler ame failure protection: Which during light up and low load
operation.
h) Boiler trip protection which shuts down all fuel in the following events :
i) Both emergency trip buttons pushed
ii) Loss of all fuel.
hi) Turbine trip.
iv) Air ow less than a minimum preset value (during start-up only)
v) Tripping of FD/ID Fans.
vi) Loss of ame.

Design Features of FSSS:

The system is basically a digital control relay logic system, employing mainly
electromagnetic
components. Even through the system is basically relay logic, the ame
scanner system unit and coal is functionally divided into unit logic, elevation logic and
comer logic.
The unit logic supervises the overall furnace conditions and monitors all critical
parameters of the fuel system, carries out furnace purge and examines all the preconditions
required for safe warm-up prior to the main fuel admission during normal
operation of the boiler, the unit logic continuously monitors the critical feed backs to
ensure safety and will trip all fuel within the preset time limit on abnormal conditions.
Removal of elevation fuel in programmed manner would be initiated by the unit logic in
response to load demand signal. If, however, by decreasing fuel demand the ring
condition approaches the point of unstable operation, additional ignitor support energy
can be automatically initiated. Besides, unit logic also provides intelligence to the
operator on the overall status of furnace conditions and alerts the operator through
alarm for correctness of operation at the appropriate time.
The elevation logic is an intermediate logic which depends on the operator or the unit
logic for initiations of start or stop actions. This also provides essential preconditions
and trip commands to corner logic as necessary depending upon the type of fuel, red.
For example if the elevation logic is designed for a pulverised fuel, the logic elements
will be designed to suit that particular type of pulveriser and its associated equipment
like feeder, hot air gate, etc. Also since the pulveriser outlet directly feeds the coal
nozzles in the four corners without any remote shut off devices for each comer, there
will not be any comw logic for this fuel. However, in case of oil ring, the comer
sequencing, etc, are performed by the respective elevation logic taken by it.
The Comer logic depends on the elevation logic commands for initiation of an action.
During manual operation the corner logic complete its own permissives based on
ignition energy availability status of various corner devices and other factors for
sequencing of individual fuel, air, or steam valve operations. In addition, in case of oil
ring, this logic performs an oil scavenging cycle before the gun is allowed to be
retracted. However, emergency trip signals originating in unit logics and transmitted via
elevation logic will bypass corner permissive logic and cause immediate shut down of
the unit.
The logic system is designed to operate on A.C. and D.C. power supplies. A.C.power
supply is backed up by power taken from another A.C source. The change over from
one A.C. supply to another takes place within 0.5 seconds. In case of loss of A.C the
trip function is accomplished by D.C logic components-where a fuel trip valve or a coal
pulverizer is trigged by D.C power. But if loss of D.C is detected, the signal is relayed
directly to the elevation logics because the unit logic trip is on D.C and therefore,
ineffective, in such a case, the corner fuel supply valves are closed, or the coal feeder
stopped by A.C. power. The loss of power trip is delayed by two seconds to allow for
over-riding power dips and transients of short duration.
The components used in the logic system include pneumatic timers with on and off
delay.latch relays, control relays, etc. Latch relays are extensively used as retentive
memory circuits so as to minimise the power consumption of the logic panel and, at the
same time.increase the life of the components.
The power distribution is on an elevation basis and includes monitoring facilities.

Arrangement of FSSS
The FSSS basically consists of the following major parts.
a) Logic cabinet.
b) Console insert.
c) Secondary air damper control.
d) Mill panel.
e) Field equipment.
f) Interface equipments.

Logic Cabinet

The heart of the system is this logic cabinet which includes all the logic
hardware. For a typical relay logic system, this includes the control relays, latch relays,
time delay relays, programme timers, ame scanner amplier system, panel distribution
and miniature circuit breakers or fuses, all pre-winded to terminal blocks.

Console Insert

The console insert contains all the push buttons and indicating lamps
illuminated push-buttons of miniature type are used to reduce the size of the console
insert.

Secondary air damper control

[http://3.bp.blogspot.com/-
W_M5CQD99ts/VE TyBQSkicI/AAAAAAAAA Us/sEAmoUXW818/s1600/fsss.png]

given gure shows the wind box assembly of a corner of

a typical tangentially red boiler which. Consists of a number of dampers located at
various elevations of fuel compartments and dampers in between the fuel
compartments. These dampers are required to modulate as a function of certain
process variables.
The various dampers are divided into two main classications depending on the type of
modulation they are required to perform.
Those dampers which regulate air surrounding a fuel compartment are termed 'Fuel Air
Dampers' whereas those dampers which regulate air adjacent to a fuel compartment
are termed "Auxiliary Dampers"
Main philosophy of control is that auxiliary air dampers are modulated to maintain a
xed differential pressure between the wind box and the furnace, whereas the fuel air
dampers are modulated in proportion to the rate of fuel red in that elevation. The
auxiliary air dampers in all elevation and corners are group-controlled in proportion to
the wind box furnace differential pressure.
Whereas the fuel air dampers of all four corners of one elevation are group-controlled in
proportions of the rate of fuel red in that elevation.

Mill panel:
Raw coal from the bunker is fed to the mill for grinding through the raw coal
feeder. The ow or lack of ow of coal to the mill is to be monitored so as to give an
alarm when there is no coal owing to the mill and also when there are other interlocks.
The Coal Flow Alarm performs this.
Field Equipments: Under the above heading, we have the eld mounted shut off
devices and signal transmitters.
The eld mounted shut off devices include:
a) Nozzle valves.
b) Header trip Valves.
c) Gun advance/retract mechanism
d) Pulveriser discharge valve.
e) Hot Air gate.
f) Secondary air damper drive
g) Ignitor cabinet.
h) Flame scanner head assembly.
i) Local gun maintenance switch box.
J) Signal initiating devices.

DEAR READERS IF YOU HAVE ANY DOUBT OR QUESTION MAIL ME AT

AVINASHSINGH1444@GMAIL.COM
Posted 20th October 2014 by Avinash Singh

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