M/S BECL, Bhavnagar 2 X 250 MW CFBC BOILER

WRITE UP ON BURNER MANAGEMENT SYSTEM

FUNCTION GROUP : START UP BURNER-1

1. Reference P & ID : AIR & FLUE GAS PATH DRG.NO. 0-97-400-80086 - 91

SCHEME OF HFO SYSTEM DRG.NO. 1-00-056-50592
DRG.NO. 1-00-056-50593
DRG.NO. 1-00-056-50599

2.2 EQUIPMENTS APPLICABLE:

The Start up burner system consists of four no of wall burners located two each on front and
rear pant legs of the combustor, facing towards the bottom of the combustor. These burners
are capable of burning LDO with air atomization or HFO with steam atomization as fuel.
However at a time one fuel alone is permitted in the burner. Combination of fuels firing ie one
SUB with LDO and other SUB with HFO is possible.

SUB –I to be started with LDO firing, and continued the boiler light up along with Bed Lances
firing with HFO. Alternately the LDO firing in SUB1 can be switched over to HFO firing, as soon
as the HFO temp, heated by AUX. steam, found O.K. The respective SUB I can be switched
over to HFO firing by shut down and then restarted with FO fuel selection.

FG Boiler Purge is to be completed before start up the SUB – I. This is a NFPA statutory and
safety requirement.

Purge is applicable at any one of the following conditions.

a) Before the first start up of the SUB,
b) After four successive unsuccessful starting of the first burner (SUB I )
c) Burner start beyond 30 min. from the completion of the purge.
d) Boiler hot start up when combustor temp < 593 C

This LDO system consists essentially of the following equipments / system.

COMMON SYSTEM

LDO SYSTEM instruments

A. DP switch across LDO suction strainer for DP high alarm (0HJF11 CP001, 0HJF12 CP001)
B. LDO PUMP PR. CONTROLLER (0HJF14 AA001)
C. LDO PR. O.K. (1HJF60 CP001)
D. LDO MASTER TRIP VALVE (1HJF60 AA101)
E. LPG PR. O.K. (1HJG60 CP002) >2.9 Kg/cm2
F. LPG MASTER TRIP VLV (1HJG60 AA101)
G. LPG VENT VLV (1HJG60 AA401)

HFO SYSTEM instruments

H. DP switch across FO suction strainer for dp high alarm (0HJF21/22 CP001)

I. HFO PUMP I / II (0HJF21/22 AP001 )
J. HFO PUMP RETURN PR. CONTROLLER (0HJF24 AA001)
K. HFO HEATER TEMP. CONTROLLER (0HJT31/32 AA001)
L. DPS across HFO HEATER OUTLET strainer for DP high alarm (0HJF31/32 CP001)
M. HFO PR. O.K. (1HJF70 CP001) 14.5 Kg/cm2
N. HFO TEMP. O.K. (1HJF70 CT001/002/003) 2 OF 3
O. HFO MASTER TRIP VALVE (1HJF70 AA101)
P. ATO STEAM PR OK (1HJT70 CP001/002/003) 2 OF 3

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 M/S BECL, Bhavnagar 2 X 250 MW CFBC BOILER
WRITE UP ON BURNER MANAGEMENT SYSTEM
FUNCTION GROUP : START UP BURNER-1

FOR SUB – I

LDO SYSTEM instruments

Q. LDO FLOW METER (1HJF60 CF001)

S. SUB-I Flow CONTROLLER / CV (1HJF61 AA001 )
T. LDO PR.LOW (1HJF61 CP901) 2 OF 3
U. LDO PR.HIGH (1HJF61 CP901) 2 OF 3
V. LDO BNR TRIP VALVE (1HJF61 AA101)
W. ATOMISING AIR PR. CONTROL VALVE (1HJN61 AA001)
X. ATOMISING PR LOW (1HJN61 CP001/002/003) 2 OF 3

AA . ATOMISING AIR TRIP VALVE (1HJN61 AA101)

BB. SUB-I COMB AIR DAMPER (1HJL11 AA001)
CC SUB-I SCANNER (1HJA71 CR001)
EE. SUB-I SCAVANGE VLV (1HJN61 AA102)
FF. SUB-I TRAVERSE ACTUATOR (1HJA71 AA101)
GG. LPG IGNITOR (1HJG71 CR301)

HFO SYSTEM instruments

HH. HFO FLOW METER (1HJF70 CF 001)

I I. HFO SUB-I Flow CONTROLLER / CV (1HJF71 AA001 )
JJ. SUB-HFO PR.LOW (1HJF71 CP001,002,003) 2 OF 3
KK. SUB-HFO PR.HIGH (1HJF71 CP001,002,003) 2 OF 3
LL. SUB-HFO RECIRCULATION VALVE (1HJF71 AA103)
MM. SUB-HFO BNR TRIP VALVE (1HJF71 AA101)
NN. SUB-1 ATOMISING STEAM PR. CONTROLLER (1HJT71 AA001)
OO. SUB-1 ATOMISING STEAM PR LOW SWITCH (1HJT71 CP001,002,003)2 OF 3
PP. SUB-1 ATOMISING STEAM TRIP VALVE (1HJT71 AA101)
QQ. SUB-I COMB AIR DAMPER (1HJL11 AA001)
RR. SUB-I SCANNER (1HJA71 CR001)
SS. SUB-I SCAVANGE VALVE (1 HJN61, AA102)
TT. SUB-I TRVERSE ACTUATOR (1HJA71 AA101)
UU. SUB-I LPG BURNER TRIP VALVE (1 HJA61 AA401)
VV. SUB-1 LPG IGNITOR (1HJG71 CR301)

3. OPERATING LOGIC

3.1 START UP OPERATION

Before starting the system all the following conditions should be satisfied.

3.1.1 PERMISSIVES

- Boiler protection SUBurners not acted.

- Any one ID FAN in service.
- Any one Purge & Seal air Blower in service.
- Any one SA FAN in service.
- SUB-I comb air damper not close (1HJL11 CG1O1B)
- Any one PA FAN in service.
- PA FLOW > MIN. -1 50 Kg/cm2
- Purge completed or combustor temp >490 C or any of the other three burners in
service signals available*
- LDO / HFO firing selected in DCS
- LPG PR. O.K. (1HJG60 CP002)>2.9 Kg/cm2
- LDO SUB-1 START command (manual)

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 M/S BECL, Bhavnagar 2 X 250 MW CFBC BOILER
WRITE UP ON BURNER MANAGEMENT SYSTEM
FUNCTION GROUP : START UP BURNER-1

IF LDO SELECTED

- LDO PUMP PR. CONTROLLER IN AUTO (0HJF14 AA001)

- LDO PR. O.K. (1HJF60 CP001)

IF HFO SELECTED

- HFO PUMP I / II RUNNING (0HJF21 AP001 /0HJF22 AP002 )

- HFO PUMP OUTLET PR. CONTROLLER IN AUTO (0HJF34 AA001)
- HFO PR. O.K. (1HJF70 CP001)
- HFO TEMP. O.K. (1HJF70 CT001/002/003) 2 OF 3
- ATO STM PR O.K. (1HJT70 CP001)
- SUB-1 SCVANGE VLV CLOSED (1HJN61 CG102B)

3.1.2 SEQUENCE

Following actions will happen when SUB-I START command given.

LDO FIRING

 SET SUB-1 Comb. Air DAMPER Controller to AUTO (1HJL11 AA001)

 LPG VENT VLV CLOSE (1HJG60 AA402)
 LPG MASTER TRIP VLV OPEN (1HJG60 CG101A)
 LPG BURNER TRIP VLV OPEN (1HJG61 CG401A)
 LPG IGNITOR ON (1HJG71 AV001)

IF FLAME ESTABLISED (Flame Scanner 1HJF71 CR001)

 ATO AIR TRIP VALVE OPEN (1HJN 61 CG101A)

 ATO AIR PR CONTROLLER AUTO (1HJN61 AA001)
 LDO MASTER TRIP VALVE OPEN (1HJF60 AA101)
 LDO BNR TRIP VALVE OPEN (1HJF61 CG101A)
 LPG MASTER TRIP VLV CLOSE (1HJG60 CG101B)
 LPG BURNER TRIP VLV CLOSE(1HJG61 CG401B)
 LPG IGNITOR OFF (1HJG71 AV001)
 LPG VENT VLV OPEN(1HJG60 AA401A)

HFO FIRING

 SET SUB-1 Comb. Air DAMPER Controller to AUTO (1HJL11 AA001)

 SUB-1 FO RECIRCULATION VALVE CLOSE (1HJF71 CG103B)
 LPG VENT VLV CLOSE (1HJG60 CG401B)
 LPG MASTER TRIP VLV OPEN (1HJG60 CG101A)
 LPG BURNER TRIP VLV OPEN (1HJG61 CG401A)
 LPG IGNITOR ON (1HJG71 AV001)

IF FLAME ESTABLISED (Flame Scanner 1HJF71 CR001)

 SUB-1 ATO STM TRIP VALVE OPEN (1HJT71 CG101A)

 SUB-1 ATO STM PR CONTROLLER-I AUTO (1HJT71 AA101)
 HFO MASTER TRIP VALVE OPEN (1HJF70 CG101A)
 SUB-1 HFO BNR TRIP VALVE OPEN (1HJF71 CG101A)
 LPG MASTER TRIP VLV CLOSE (1HJG60,CG101B)
 SUB-1LPG BURNER TRIP VLV CLOSE (1HJG61 CG401B)
 LPG VENT VLV OPEN (1HJG60 AA401A)

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 M/S BECL, Bhavnagar 2 X 250 MW CFBC BOILER
WRITE UP ON BURNER MANAGEMENT SYSTEM
FUNCTION GROUP : START UP BURNER-1

3.2 SHUT DOWN OPERATION

3.2.1 PERMISSIVES

3.2.2 SEQUENCE

Following actions will occurs automatically, when SUB-I STOP command given or TRIP
occurs.

LDO FIRING

 SUB-1LDO BNR TRIP VALVE CLOSE (1HJF61 CG101B)

 LDO MASTER TRIP VALVE CLOSE (1HJF60 CG101B) ONLY IF SUB-II/III/IV
BNR TRIP VALVE ARE CLOSED.
 SUB-I SCAVANGE VLV OPEN (1HJN61 CG102A)
 AFTER SCAVANGE TIME OVER SUB-I SCAVANGE VLV CLOSE (1HJN61
CG 102B)
 SUB-I ATO AIR TRIP VALVE CLOSE (1HJN61 CG101B)


HFO FIRING

 SUB-1 FO BNR TRIP VALVE CLOSE (1HJF71 CG101B)

 SUB-1 HFO LONG RECIRCULATION VLV OPEN (1HJF71 CG103A)
 SUB-I SCAVANGE VLV OPEN (1 HJN61 CG102A)
 AFTER SCAVANGE TIME OVER SUB-I SCAVANGE VLV CLOSE
(1HJN61 CG102B)
 SUB-1 ATO STM TRIP VALVE CLOSE (1HJT71 CG101B)

3.3 PROTECTION

Burner will trip and trip indication / signal will ON, when any one of the following conditions
accurse.

 Emergency push buttons activated.

 Boiler Protection 2 SUB acted
 Running ID FAN tripped
 Running SA FAN tripped
 Running PA FAN tripped
 Respective fuel LDO / HFO pr. V. High
 Respective fuel LDO / HFO pr. V. low
 Flame failure
 DP between HFO Vs Atomising Steam Low if HFO selected
 HFO temp low if HFO selected
DP between LDO Vs Atomising Air Low if LDO selected

3.4. NOTE:

If combustor temperature > 600 deg.C,. Hot start up can be done without SUB in
service.

If start up of the SUB is delayed more than 30 min from purge complete, again purge
to be done

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 M/S BECL, Bhavnagar 2 X 250 MW CFBC BOILER
WRITE UP ON BURNER MANAGEMENT SYSTEM
FUNCTION GROUP : START UP BURNER-1

SUB-I can be started independently irrespective of SUB – II/III/IV is in operation with

HFO / LDO.

Operation of HFO master trip valve and long re – circulation valve of each SUB are by
remote manual..

For SUB II,III and SUB IV the function group write up is same as above. However
the instrument tag numbers will be different for other burners.

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