ID/FD/PA fans LOGIC

SYSTEM

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PURGE PERMISSIVES
All HFO nozzle valves closed
All pulverisers OFF
All feeders OFF
No MFT condition present
All scanners senses no flame
All Auxiliary Air dampers modulating

TO
FSSS

Both PA fans OFF

All Mill HAGs closed
Air flow more than 30% and less than 50%
HFO trip valve is closed
Wind box to furnace DP is
adequate
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November 27, 2016

Both FD fans OFF

Both ID fans OFF.
Inadequate water wall circulation for more than 5 seconds.
Loss of Reheat Protection for greater than 10 seconds.
All BFPs tripped.
Drum level very high for more than 10 seconds (2/3 logic)
Drum level very low for more than 10 seconds (2/3 logic)
Furnace pressure very high (2/3 logic)
Furnace pressure very low (2/3 logic)
Loss of all fuel.
All feeders OFF and loss of AC Supply to the elevation in service.
Unit flame failure.
Loss of Unit Critical Power for more than 2 seconds
Both Secondary APHs OFF.
Loss of 220 V DC Supply for more than 2 seconds.
Air flow less than 30% and boiler load not greater than 30%.
Manual Emergency trip.

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Both FD fans OFF

Both ID fans OFF
Inadequate water wall circulation for more than 5 seconds
Loss of Reheat Protection for greater than 10 seconds
All BFPs tripped
Drum level very high for more than 10 seconds (2/3 logic)
Drum level very low for more than 10 seconds (2/3 logic)
Furnace pressure very high (2/3 logic)
Furnace pressure very low (2/3 logic)
Loss of all fuel

MFT
RELAY

All feeders OFF and loss of AC Supply to the elevation in service

Unit flame failure
Loss of Unit Critical Power for more than 2 seconds
Both Secondary APHs OFF
Loss of 220 V DC Supply for more than 2 seconds
Manual Emergency PB trip
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Air flow less than 30% and boiler load not greater than 30%

 Arming:

1. ALL ID FANS OFF

Always armed

Logic:

Both ID Fans OFF Contact sensed by MFT panels

Purpose:

Anticipatory protection to prevent furnace pressurization

Loss of furnace pressure control and balanced draft

Protection Delay:
0 sec INSTANT.

Protection Check:

Simulate the signals from ID Fans Electrical Control

Circuit

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 Arming:

2. ALL FD FANS OFF

Always armed

Logic:

Both FD Fans OFF Contact sensed by MFT panels

Purpose :

Anticipatory protection to prevent reducing firing

condition
Loss of total air flow control and balanced draft

Protection Delay:
0 sec INSTANT.

Protection Check:
Simulate the signals from FD Fans Electrical Switchgear
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 Arming:

3. LOSS OF ALL FUEL

Any HFO/LFO nozzle valve NOT closed

Logic:

All LFO cut off AND All HFO cut off AND All Feeders OFF
Initiation of a mandatory purge cycle to restore furnace

Purpose:
Backup protection to trip remaining equipment (eg. PA
Fans)
0 sec INSTANT.

Protection Check:
Keep oil manual isolating valves in any one elevation any
one corner (done by OPN), simulate status of manual
valve (done by C&I), then give sequence start command
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2016 corner
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 Arming:

4. FLAME FAILURE

Any Feeder Proven for 2 sec

Logic:

All Elevations A to K voted NO Flame

Eg. Elevation A voted no flame means
(AA 3/4 fireball scanners sense no flame AND AB 3/4
fireball scanners sense no flame AND AB 2/4 oil guns not
proven in service) OR
Feeder A Not Proven for 2 sec
Stop firing under unstable flame fireball conditions

Protection Delay:
0 sec INSTANT.

Protection Check:

Simulate feeder proven status without any oil in service

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5. FURNACE PRESSURE VERY HIGH

Arming:
Always armed

Logic:

2 out of 3 pressure switches sense furnace pressure

very high > +150 mmwc

Purpose:

To stop fuel firing under explosive tendency of furnace

Prevent furnace structural distortion

Protection Delay :

0 sec INSTANT.

Protection Check:

Simulate from protection instrument, or by actual

pressurization if agreed by Operation Head.
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6. FURNACE PRESSURE VERY LOW

Arming:
Always armed

Logic:

2 out of 3 pressure switches sense furnace pressure

very low < -175 mmwc

Purpose:

To stop fuel firing under implosive tendency of furnace

Prevent furnace structural distortion

Protection Delay:
0 sec INSTANT.

Protection Check:

Simulate from protection instrument, or by actual

depressurization if agreed by Operation Head.

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7. DRUM LEVEL VERY HIGH

Arming:
Logic:

Always armed

2 out of 3 logic derived from hydrastep-left-1, hydrastepright-1 and drum level transmitter > 250 mm

Purpose:

To prevent water carry over to superheater headers and

subsequently to turbine

Protection Delay:
10 sec.

Protection Check:

Actual (increase feed water flow slowly until level

reaches trip limit).

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8. DRUM LEVEL VERY LOW

Arming:
Always armed

Logic:

2 out of 3 logic derived from hydrastep-left-2, hydrastepright-2 and drum level transmitter < -375 mm

Purpose:

To prevent waterwall tubes starvation

To prevent BCW pumps starvation

Protection Delay:
5 sec.

Protection Check:

Actual (decrease feed water flow slowly until level

reaches trip limit).

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 Arming:

9. ALL BFP OFF

Always armed

Logic:

Both TDBFPs sensed Not Working AND MDBFP

sensed OFF

Purpose:

Anticipatory protection for Drum Level Very Low

To prevent economizer tubes starvation

Protection Delay :
10 sec.

Protection Check :

Simulate OFF contact of all BFP from BFP control panel

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 Arming:

10. ALL SAH OFF

Always armed

Logic:

Both Secondary Air Heaters: electric motor OFF AND air

motor OFF

Purpose:

Preventing poor furnace combustion due to low

secondary air temperature
Preventing flue gas damper isolation in all air heaters

Protection Delay:
5 sec.

Protection Check :
Actual.

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11. WATERWALL CIRCULATION

INCORRECT
Arming:
Boiler ON

Logic :

All BCW OFF (OR) 2/3 running BCW DP < 0.68 ksc

Purpose:

Preventing damage to waterwall tubes due to insufficient

cooling flow/circulation

Preventing DNB (departure from nucleate boiling)

Protection Delay:
5 sec.

Protection Check:
Equalizing DP transmitters to simulate DP low.

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12. TOTAL AIR FLOW < 30%

Arming:
Always armed

Logic:

Total Air Flow (Primary Air + Secondary Air) < 30% of full load
air flow (30% of 1800 Tph = 540 Tph)

Purpose:

Ensuring absolute minimum required quantity of air flow even

during startup
Preventing localized accumulation of unburnt oil during startup

Protection Delay :
0 sec - INSTANT.

Protection Check :
Actual.

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13. REHEATER PROTECTION

Arming:

HP bypass AND LP bypass charged for the first time > 2%

Logic:

Generator Circuit Breaker Open AND (HP bypass OR LP bypass

Fail to Open)
OR
Reheater Inlet (HP) OR Outlet Path (IP/LP) Blocked

Purpose:

Ensuring absolute minimum required quantity of air flow even

during startup
Preventing localized accumulation of unburnt oil during startup

Protection Delay:
10 sec.
Protection Check:
Actual.
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 Arming :

14. LOSS OF 24V DC

Always armed

Logic:

If 24V supply to any 2 MFT panels is lost, it will initiate a

hardwired MFT protection through 220V contactor circuit.

Purpose:

If 24V fails, the processors cannot execute any logic, leading to

unsafe condition

Protection Delay :
0 sec INSTANT.

Protection Check :
By 24V breaker simulation in MFT panel.

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 Arming:

15. LOSS OF 220V DC

Always armed

Logic:

If 220V supply to any 2 MFT panels is lost, it will initiate a soft

MFT protection through processor logic.

Purpose:

If 220V fails, backup protection for 24V failure will be

unavailable.

Protection Delay:
2 sec.

Protection Check:
By 220V breaker in MFT panel.

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17 . 2/3 PROCESSORS FAIL/FROZEN

Arming:
Always armed

Logic:

If any 2 MFT processors out of 3 go into failed state, or if any 2

MFT processors go into frozen output state, it will initiate MFT
protection.

Purpose:

This ensures that at least 2 processors are in healthy condition

at any point of time when boiler is in service.
Failure of processors leads to unsafe condition

Protection Delay :
0 sec - INSTANT.

Protection Check:
By actually creating frozen output state in processors.

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17. 2/3 PROCESSORS COMMN FAIL

Arming:

Always armed

Logic:

If any 2 MFT processors out of 3 stop communicating with the

Ethernet network (redundant net-A and net-B), they will initiate
MFT protection

Purpose:

This ensures that at least 2 processors are communicating

properly at any point of time when boiler is in service.
Failure of communication leads to malfunction of protection
circuit

Protection Delay:
0 sec - INSTANT.

Protection Check:
By actually isolating network connections of the processors.
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 Arming:

18. EMERGENCY TRIP

Always armed

Logic:

If both Desk Emergency Push Buttons pressed together (OR)

If both Backup Panel Push Buttons pressed together (OR)
If MFT is confirmed through popup from any workstation PC

Purpose:

This facility allows the operation desk engineer to directly trip

the boiler in case of any operational emergency eg. Boiler Tube
Leakage, Furnace excessive Clinkering, HFO oil leakage during
startup, turbine related emergencies etc.

Protection Delay :
0 sec - INSTANT.

Protection Check :
By actually operating push buttons/through PC.
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POST-TRIP PURGE FANS TRIP

Arming:

Boiler not firing fuel for 5 min (MFT may or may not be reset)

Logic:

If furnace pressure very high > 150 mmwc OR very low < -175
mmwc (AND)
Air Flow > 30% THEN
TRIP all ID Fans and FD Fans

Purpose:

This protection safeguards furnace against furnace pressure

very high OR very low when boiler is NOT firing.

Protection Delay :

0 sec INSTANT (5 min delay in arming circuit)

Protection
Check:
By simulation at source.
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RUNBACK GRADED MILL TRIP

Arming:
More than 4 mills in service

Logic:

If any major auxiliary (eg. ID, FD, PA, BFP) trips and standby is
not available, unit load is automatically reduced according to
the new capability
Mills are tripped one by one starting from top running mill, at 2
sec delay, until 4 running mills from bottom remain.

Purpose:

This interlock achieves the fastest possible load reduction, and

requires NO intervention of desk engineer

Protection Delay:

Varies from 1 sec to 1 min according to type of auxiliary

Protection Check:

Simulated at initiating point.

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THANK YOU
QUESTIONS ?

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P&I OF BOILER AUXILLARIES

A. FD FAN

START PERMISSIVES

Blade pitch position minimum.

Discharge damper fully closed.

Lube oil pressure adequate.

Control oil pressure adequate.

Oil tank level normal.

Bearing temperature not high.

One ID Fan running AND other FD fan not

running.
OR Both ID Fan running

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TRIPS

Fan bearing temperature very high

Post purge furnace pressure very high/ very low
Outlet damper fail to open in set time

(3 min)

No ID fan running or one ID fan and one FD fan

already in service.

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PA FAN
START PERMISSIVES

Blade pitch minimum

Lube oil pressure adequate
Control oil pressure adequate
Bearing temp. not high
Discharge damper closed.
Lube oil tank level adequate
No MFT & Cold air damper closed
At least one FD fan is running and
PAPH A/B in service & respective air inlet/ outlet
dampers are open
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TRIPS
Fan bearing temperature very high.
Trip from FSSS (MFT).
Discharge damper fails to open.

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ID FAN
START PERMISSIVES
Hyd. coupling Scoop position minimum.
Inlet guide vane position minimum.
Bearing temperature not high.
Oil temp. and oil level in Hyd. coupling OK.
Lube oil pressure adequate.
Both inlet and outlet dampers closed.
Other ID fan not running or Any FD fan running.

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TRIP CONDITION
Fan/Motor bearing temperature very high.
Lube oil pressure very low.
Post purge furnace pressure Hi/Low from FSSS.
Discharge dampers/ suction damper fail to open
within specified time (3 min.)
Hydraulic coupling bearing temp. very high
Hydraulic coupling oil temp. very high.
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SGWC PUMPS: (CC Pumps)

PERMISSIVES
Discharge valve 1 open.
Discharge valve 2 open.
Motor cavity temp. not high.
Pump cavity suction manifold differential
temp. not high.
Motor cooling water flow adequate.
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TRIPS

Any of the discharge valves not fully open.

Motor cavity temp. high (60 deg. C) for more
than 5 Sec.
Electrical protection trip/ EPB pressed.

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Run back operation

Tripping of PA Fan or FD Fan
PA header pressure low/very low
Sequential tripping of Mills/Feeders

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