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    Furnace Safeguard and Supervisory System

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    Nilesh Duryodhan
    This document describes a furnace safeguard and supervisory system (FSSS) that monitors operations related to fuel admission and other parameters to ensure boiler safety. FSSS continuously supervises fuel firing and shuts down the boiler if dangerous conditions arise. It follows strict logics and sequences to safely control startup, operation, and shutdown. The system hardware includes switches, valves, sensors and logic controllers. FSSS aims to prevent explosions by carefully coordinating fuel levels, airflows, ignition, and more during all phases of boiler operation.

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    Furnace Safeguard and Supervisory System

    Uploaded by

    Nilesh Duryodhan
    2K views36 pages
    This document describes a furnace safeguard and supervisory system (FSSS) that monitors operations related to fuel admission and other parameters to ensure boiler safety. FSSS continuously supervises fuel firing and shuts down the boiler if dangerous conditions arise. It follows strict logics and sequences to safely control startup, operation, and shutdown. The system hardware includes switches, valves, sensors and logic controllers. FSSS aims to prevent explosions by carefully coordinating fuel levels, airflows, ignition, and more during all phases of boiler operation.

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    This document describes a furnace safeguard and supervisory system (FSSS) that monitors operations related to fuel admission and other parameters to ensure boiler safety. FSSS continuously supervises fuel firing and shuts down the boiler if dangerous conditions arise. It follows strict logics and sequences to safely control startup, operation, and shutdown. The system hardware includes switches, valves, sensors and logic controllers. FSSS aims to prevent explosions by carefully coordinating fuel levels, airflows, ignition, and more during all phases of boiler operation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    2K views36 pages

    Furnace Safeguard and Supervisory System

    Uploaded by

    Nilesh Duryodhan
    This document describes a furnace safeguard and supervisory system (FSSS) that monitors operations related to fuel admission and other parameters to ensure boiler safety. FSSS continuously supervises fuel firing and shuts down the boiler if dangerous conditions arise. It follows strict logics and sequences to safely control startup, operation, and shutdown. The system hardware includes switches, valves, sensors and logic controllers. FSSS aims to prevent explosions by carefully coordinating fuel levels, airflows, ignition, and more during all phases of boiler operation.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 36
    At a glance
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    The key takeaways are that FSSS continuously monitors operations related to fuel admission and other parameters to ensure boiler safety. It aims to prevent explosions during startup, shutdown and low load operations.

    An FSSS is a burner management system that monitors critical parameters of the fuel firing system to safely admit fuel into the furnace. It ensures safe furnace operations through continuous monitoring.

    The different logics used in FSSS are unit logic, elevation logic and corner logic. Unit logic supervises overall furnace conditions. Elevation logic controls startup/stopping of elevations. Corner logic controls corner valves.

    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 off

    5. All Coal feeders Off


    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
    elevation’s 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 elevation’s 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

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