Professional Documents
Culture Documents
Instrumentation
K Karthikeyan
Manager
Controls & Instrumentation
BHEL, Tiruchirappalli
Email : karthi@bheltry.co.in
Boiler C&I
INTRODUCTION
PART I - BOILER
PART 2 - INSTRUMENTATION
PART 3 - CONTROLS
Boiler C&I
Boiler
Controls &
Instrumentation
Boiler C&I
Boiler C&I
Boiler C&I
Functions
Proposal Engineering
Contract Engineering
Product Engineering
Quality Assurance &
Control
Field Engineering
Research & Development
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Proposal Engineering
Boiler C&I
Proposal Engineering
Scope of Work
Project Estimate
Offer submission
Offer evaluation
by customer
Award of
contract
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Proposal Engineering
In summary, the purpose is to draw-up
- Scope of Work
- Project Estimate
of the project.
Deliverables :
-
Boiler C&I
Scope of Work
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Scope of Work
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Offer evaluation
The offers get evaluated at the customer
end.
Customer awards the contract on a
technically qualified bid with the lowest
price.
The award of contract is indicated by a
Letter of Intent received from the customer.
Boiler C&I
Award of
contract
Boiler C&I
Contract Engineering
Boiler C&I
Contract Engineering
Packages
SG integral C&I(Trichy)
Station C&I(PEM or customer)- in
case of BTG or Turnkey
SG integral electricals(Trichy)
Station Electricals(PEM or customer)in case of BTG or Turnkey
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Contract Engineering
The role involves system level contract
coordination for the boiler C&I area.
Applicable PGMA List
Sub Delivery check list.
Boiler Contract Regular activity(BCR)
schedule
00 PG list(erection documents).
Applicable O&M documents.
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Contract Engineering
System Engg. Documents involved :
Piping&Instrumentation
Diagrams(P&IDs)
Measurement & control
recommendations
Automatic control schemes
Interlock & protection schemes
Boiler C&I
Boiler C&I
Boiler C&I
Product Engineering
Boiler C&I
Product Engineering
Detailed design of Boiler C&I
products & systems
Digital controls
Analog controls
Electrical systems &
cables
Field instruments
Special instruments
Actuators
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Product Engineering
Digital Controls
Boiler C&I
Product Engineering
Electrical systems
Boiler C&I
Product Engineering
Special instruments
Boiler C&I
Product Engineering
Electrical and C & I engineering design
Release of indents for C & I sub-delivery items.
Evaluation of technical offers for bought-out
items
Technical Delivery Conditions (TDC)
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Field Engineering
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Field Engineering
The role involves
Providing technical support / trouble shooting of
C&I products / system during
- Erection & commissioning stage of project
Boiler C&I
Boiler C&I
Boiler C&I
Boiler Basics
Boiler C&I
BOILER CLASSIFICATION
Boiler C&I
BHEL BOILERS
Power Boilers
Up to 600 MW rating(Coal, oil and gas fired - Subcritical)
Up to 800 MW - Supercritical
Nuclear steam generators
Up to 235 MW rating
Industrial boilers
Up to 450 Tonnes/hour rating
Fertilisers, Petrochemical, Steel & Paper industries
Wide range of fuels- Oil, Gas, BFG, Bagasse, Black liquor.
Boiler C&I
Schematic of a boiler
Boiler C&I
UTILITY BOILERS - ESSENTIAL COMPONENTS
Boiler C&I
CIRCULATION SYSTEMS
Natural circulation
Controlled circulation
Once through
Circulation ratio :
Mass rate of water fed to the steam generating tubes to the
mass rate of steam generated.
Natural circulation
Controlled circ
Once through
6
4
1
Boiler C&I
Fans
1.
Axial
Impulse type - IGV Control.
Reaction type - Blade pitch Control.
2. Radial
Inlet damper control, Variable speed control;
Variable speed control by two speed motor,
Hydraulic coupling or Variable frequency drive.
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Radial
Fan- Tiruchirappalli
Bharat Heavy Electricals Limited
Boiler C&I
Axial Reaction
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
RADIAL FANS - SPEED CONTROL
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AIRHEATER
Regenerative type
Tubular type
( Rotating drive )
Boiler C&I
SOOTBLOWERS
Remove ash & slag from pressure part tubes
Types
Long retractable sootblowers - traverse & rotary motors
Half retractable sootblowers- traverse & rotary motors
Rotary blowers - rotary motor
Wall blowers - traverse & rotary motors
Furnace temperature probe - Used during boiler start up
Boiler C&I
Coal
Oil Gas
H/C ratio
Natural gas 0.3
Coal
0.07
2500
Fluidised bed
Boiler C&I
FUELS & COMBUSTION
Rapid combustion
High temperature
&
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Boiler Instruments
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Boiler C&I
Instrumentation
representation- ISA
First letter
P-Pressure
T-temperature
F- Flow
A- Analytical
Succeeding letters
A- Alarm
I- Indicate
R- Record
Q- Integrate
C- Control
S- Switch
T- tansmitter
E- Element
P- Pocket
W- Well
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Boiler Controls
Boiler C&I
BOILER CONTROLS
Continuous control :
Objective
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BOILER CONTROLS
Boiler C&I
Auto control system.
Master demand
Combustion and draft control
Feed-water control
Steam-temperature control
Boiler C&I
Master demand
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Combustion control
Objective :
Fuel is consumed at a rate that exactly matches the Steam demand.
Fuel is consumed safely, so that the energy is released without risk to plant,
personnel or environment
Boiler C&I
Combustion control
Fuel FLOW
FT
AIR FLOW
PT
FT
f(x)
P
A
I
T
SP
P
A
I
T
LO SELECT
Fuel CONTROL
Fuel Feed
SP
HI SELECT
P
A
I
T
AIR CONTROL
f(x)
Air Feed
AIR
DAMPER
Bharat Heavy Electricals Limited - Tiruchirappalli
67
Boiler C&I
Boiler C&I
Feedwater control
Objective :
To supply enough water to the boiler to match the evaporation rate.
Water level in the drum indicates amount of water in boiler
Actual Steam Flow - Used to determine required feedwater during
transient conditions when level may not be accurate.
Difference between Actual steam flow and Actual Feedwater Flow is
added to the level error to form the Feedwater demand.
Feedwater demand drives the feed control station to adjust feedwater
sa as to maintain the drum level to normal value.
Boiler C&I
Feedwater control
DRUM
STEAM
PRESSURE
PT
FLOW
FT
f(x)
FEEDWATER
LT
f(x)
X
FLOW TEMPERATURE
PT
FT
TE
f(x)
X
PRESSURE AND
TEMPERATURE
COMPENSATION
PRESSURE
COMPENSATION
f(x)
TEMPERATURE
CONDENSATION
SET POINT
A
M/A CONTROL
STATION
f(x)
FINAL
CONTROL
DEVICE
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Two types of dampers Fuel air dampers & Auxiliary air dampers
Maintains proper windbox air flow distribution
0 to 30 % unit load, all auxiliary dampers modulated to
maintain windbox to furnace differential pressure
Above 30% unit load, BMS closes elevations of
auxiliary dampers that are not required for elevations of
fuel currently in service
Fuel air dampers are positioned on an elevation basis as a
function of the
corresponding coal feeder speed
High windbox to furnace differential pressure opens all
the secondary air dampers
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
Boiler C&I
Scope :
Sequence control of starting and protection &
interlocking of boiler auxiliaries
FD fans
ID fans
PA fans
Airheaters
Dampers
Valves
Boiler C&I
( FSSS )
Boiler C&I
Tangential Windbox
Boiler C&I
SECONDARY AIR
SECONDARY AIR
Boiler C&I
Fireball Tangential Firing
Boiler C&I
CAUSES OF FURNACE EXPLOSIONS
An interruption of
Fuel
or
Air supply or
Ignition energy
Boiler C&I
CAUSES OF FURNACE IMPLOSIONS
Boiler C&I
FSSS
FUNCTIONS OF FSSS
1. FURNACE PURGE SUPERVISION
2. SECONDARY AIR DAMPER MODULATION AND ON-OFF
CONTROL AND SUPERVISION
3. IGNITOR ON-OFF CONTROL AND SUPERVISION
4. LIGHT OIL ON-OFF CONTROL AND SUPERVISION
5. HEAVY OIL ON-OFF CONTROL AND SUPERVISION
6. PULVERIZER AND FEEDER ON-OFF CONTROL AND
SUPERVISION
7. FLAME SCANNER INTELLIGENCE AND CHECKING
8. BOILER TRIP PROTECTION.
Boiler C&I
FSSS
F - FURNACE
S - SAFEGUARD
S - SUPERVISORY
S - -SYSTEM
FSSS ENSURES SAFE FURNACE OPERATING CONDITIONS DURING
START UP
LOW LOAD OPERATION
SHUT DOWN.
Boiler C&I
FSSS
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FSSS
UNIT LOGIC
ELEVATION LOGIC
CORNER LOGIC
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FSSS
MANUAL TRIP
ANY
Boiler C&I
FSSS
ALL PULVERIZERS
ALL FEEDERS
ALL OIL GUNS
ALL IGNITORS
IT CLOSES
1. IGNITOR
2. LIGHT OIL TRIP VALVES
3. HEAVY OIL TRIP VALVES
Boiler C&I
Scanner Fan logic
Boiler C&I
Seal Air Fan Control
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FSSS
<
<
<
<
START
PULVERIZER ON FEEDBACK
OPEN HOT AIR GATE
WAIT TILL PULVERIZER COMES TO TEMPERATURE
( 140F )
START FEEDER ( AT MINIMUM FEEDER SPEED )
COAL FLOW INDICATOR OR PULVERIZER AMPERE (
( WITH IN 5 SECONDS )
FIFTY SECONDS
FEEDER SPEED RELEASED TO AUTOMATIC CONTROL
FUEL AIR DAMPER OPENED
FUEL AIR DAMPER MODULATED TO AUTOMATIC
CONTROL.
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
PULVERIZER START REQUIREMENTS
FSSS
B.
C.
D.
E.
Boiler C&I
FSSS
B.
C.
D.
E.
F.
Boiler C&I
FSSS
Boiler C&I
FSSS
Boiler C&I
FSSS
FEEDER CONTROL
A.
B.
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FSSS
BOILER TRIP
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FSSS
<
<
<
Boiler C&I
FSSS
<
<
<
Boiler C&I
FSSS
ARRANGEMENT OF SYSTEM
FSSS - MAJOR PARTS
LOGIC CABINET
CONSOLE INSERT
SECONDARY AIR DAMPER PANEL
MILL PANEL
FIELD EQUIPMENTS
CUSTOMER SUPPLIED INTERFACE
EQUIPMENT.
Boiler C&I
HEA Advances
Atomising valve opens
Corner oil valve opens
HEA sparks
Flame scanner picks up flame
HEA retracts
Corner valve closes if flame is not
sensed.
Bharat Heavy Electricals Limited - Tiruchirappalli
Boiler C&I
FSSS Oil gun start up timing sequence
THANK YOU