FURNACE SAFEGUARD AND

SUPERVISORY SYSTEM

Aseem Ramteke
J.E.
Khaparkheda TPS
K-53
 FURNACE SAFEGUARD
SUPERVISORY SYSTEM
Furnace safeguard supervisory system popularly

called FSSS continuously monitors the operations

related to fuel admission and some other vital
parameters to ensure safety of the Boiler.
Generally furnace oil or any kind of fuel is
susceptible to explosion hazards.
Majority of explosion occurs during start up, shut

down and low load operations.

 FURNACE SAFEGUARD
SUPERVISORY SYSTEM
There are many steps that must be followed by the operator

to admit a fuel in to the furnace safely and properly.

In high capacity boilers, where fuel input rate is very high

major furnace explosions can result from the ignition of un-

burnt fuel accumulated in the first one or two seconds.
Human reaction time to such situations is inadequate. So

there is a need for proper burner management system called

as FSSS is installed in the Boilers. Every operation related to
fuel admission is accomplished through FSSS.
 FSSS HARDWARE
Pushbutton switches for initiating operations
related to Fuel Oil and Coal admission,
Alarm windows on desk and panels for indicating
current status of coal mills, oil elevations and flame
scanner at every corner.
Relay Panels in the Relay room
Oil admission valves at every corner
Oil trip valves and re-circulation valves controlling
the oil to headers
 FSSS HARDWARE
Limit switches sensing status of the valves in
oil admission
Flame scanners
Pressure and Temperature switches
Electro- pneumatic Solenoid valves
Relay panels consisting of Relays, Timers and
Memory Units.
Logics in FSSS
1)Unit Logic

2) Elevation Logic

3) Corner Logic
UNIT LOGIC
It supervises the overall furnace conditions by
monitoring all critical parameters of fuel firing
system

Supervises furnace purge.

If there is a likelihood of dangerous condition,

it trips the boiler.
ELEVATION LOGIC
Startup and stopping actions for the elevation
are carried out through the elevation logic.

Input to this logic is from operators for start

and stop commands of the elevation also trip
commands from Unit logic.

It also provides essential trip commands for

corner logic.
CORNER LOGIC
It controls and supervises the corner valves
i.e. Oil Valves. Atomizing Valves and Scavenge
valves.

Trip signals from unit logic or elevation logic

overrides the commands from corner logic.
LOGIC GATES USED IN
FSSS
AND GATE
OR GATE
NOT GATE &

DELAY TIMER
AND GATE
OR GATE
NOT GATE
DELAY TIMER
FUNCTIONS OF FSSS
Furnace Purge Supervision
Igniter Control
Warm up fuel control
Pulveriser Control
Secondary Air damper Control
Flame scanner intelligence
Boiler Tripping
FURNACE PURGE
Purpose of this control is to ensure that furnace is
always purged prior to Boiler Light up.
When boiler trips on protection or otherwise, there is
a possibility of accumulation of unburnt fuel in the
furnace. This unburnt fuel need to be driven out prior
to readmission of oil for lighting up the boiler.
Purging is achieved by establishing a sufficient airflow
by running one air cycle for predetermined time 5
minutes for 210 MW and 9 minutes for 500 MW
Boilers.
This is the first operation that has to be carried out for
lighting up the boiler.
Furnace Purge Conditions
1. All igniters retraced in case of HEA igniters/All
igniter valve closed incase of HSD Igniters

2. All heavy oil valves closed

3. All Light oil valves

4. All pulverisers of

5. All Coal feeders Of

6. All flame scanners sense no flame

Furnace Purge Conditions
7.All hot air gates closed and cold air dampers
open 5%.

8. All auxiliary air dampers modulating

9. Igniters trip valves closed

10. Heavy oil trip valves closed

11. Light Oil Trip valves are closed

12. No Boiler trip

Furnace Purge Control
 LOTV Open/Close
Before Boiler light up with Light Diesel oil, LOTV
must be opened by giving open command the
desk.

Other conditions to be satisfied are

1. No Boiler Trip
2. All Corner Valves closed
3. LDO Pressure adequate
4. LOTV Close command not persisting
 LOTV Open/Close
LOTV closes when
1. Close command through push button switch
is initiated
OR
2. Boiler trips.
OR
3. After a delay of 3 seconds when any warm up
oil elevations Corner valve is NOT CLOSED
 LOTV Open/Close
LOTV closes when

1. Close command through push button switch is initiated OR

2. Boiler trips. OR
3. After a delay of 3 seconds when any warm up oil
elevations Corner valve is NOT CLOSED

AND

a. If LDO Pressure drops to LOW value

OR
b. If dP between atomizing air and LDO is low
LOTV ON/OFF
Pulveriser Ready
Permissive
1. Pulveriser outlet temperature NOT HIGH

2. Tramp Iron Hopper Valve Open

3. Feeder Inlet gate Open

4. No Primary Air Fan Trip

5. Pulveriser Discharge Valve open

6. No Pulveriser trip
Pulveriser Ready
Permissive
7. No Pulveriser stop command existing from Local or
control desk

8. Seal air valve open

9. Cold air gate open

10. No Boiler trip AND

a. Any Feeder is ON OR

b. Burner tilt horizontal AND Air Flow less than

40%.
Pulveriser Ready
Permissive
Pulveriser Ignition Permissive
For Pulveriser A

Pulveriser B is running with 50% loading AND

Boiler Load is More than 30%

OR

Elevation AB in service with 3 out of 4 Guns

established.
Pulveriser Ignition Permissive
Pulveriser B Ignition Permissive:-

Pulveriser A or C running at 50% loading AND

Boiler Load is more than 30%

OR

Oil Elevation AB in service with 3 out of 4

guns established
WIND BOX DAMPERS
Auxiliary Air Dampers:

During furnace purge and when load is less than 30%.

FSSS modulates the auxiliary air dampers to maintain
a low wind box Pressure.

When load increases beyond 30% the modulation is for

a higher wind box pressure, which is achieved by
closing dampers near elevation not in service.
WIND BOX DAMPERS
When warm up oil is in service, the auxiliary air
damper of AB elevation opens to a predetermined
position.

When heavy oil is in service, the auxiliary air is

allowed to be controlled by opening depending on
oil pressure.

When one FD fan trips, then all auxiliary and fuel

air damper open wide.
Fuel air dampers:

All the air dampers are shut on elevations

where there are no feeders in service.

After starting of feeder, the fuel air damper of

that elevation is allowed to be controlled with
feeder speed.
BOILER PROTECTIONS
BOILER PROTECTIONS
OBJECTIVES ACHIEVED BY FSSS

Safe Furnace Operations.

Smooth Light up of Furnace.

Withdrawing of Boiler safely as and when

required.

Protective system for Boiler.

THANK YOU