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 HONVs closed
No close / Trip command
Open PB depressed

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HOTV Interlocks
To Open HOTV : Permissives
SET II

All HONVs 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
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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
STEAM HEADER

HFO Supply Scheme

HFO PUMP-1

HFO
HTR-1

HFO PUMP-2
HFO
HTR-2

HFO
HTR-3

HFO PUMP-3

FROM HFO
DAY TANK

TO BOILER
FRONT

TO HFO
DAY TANK
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HFO Scheme At Boiler Front

HOTV

HOFCV

FT
AB ELEVATION

CD ELEVATION
M

SHORT
RECIRCULATION

FT

EF ELEVATION

HORV
HFO
SUPPLY
LINE

HFO
RETURN
LINE

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Atomizing Steam Scheme

AB ELEVATION

CD ELEVATION

EF ELEVATION

Oil Gun Connection

HFO NOZZLE
VALVE

SCAVENGE
VALVE

OIL GUN

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.

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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
Nozzle valve proven
All HFO Elevation Trip
All feeders off

2 SEC

All HFO Nozzle

valve closed
HOTV NOT OPEN

All feeders off

Loss of all
fuel trip
2 SEC

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
Failure
Trip

Elevation DE No Flame Vote

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
Feeder D Off

2 Sec

Elevation DE
No Flame Vote

Elevation BC Scanners No Flame

Feeder C Off
Feeder B Off

2 Sec

Elevation BC
No Flame Vote

Elevation AB Any HFO

Nozzle Valve Not Closed
Elevation AB 2/4
Nozzle Valve Not Proven
Elevation AB
Scanners No Flame

Feeder A Off

Elevation AB
No Flame Vote

2 Sec

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ELEVATION GH ANY HFO

NOZZLE VALVE NOT CLOSED

Flame Failure Vote Logics

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 HONVs open
OR
Boiler load > 30 % and Feeder - B speed > 50 % ( > 30 T/hr.)
For Mill B
AB elevation proven 3/4 HONVs 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 < 5wc
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
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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