Manish Dhruw

Asst Manager
14843
Cpp-540
 Boiler Interlock - A Boiler Interlock is an arrangement of heating controls. It
ensures the boiler does not fire when there is no demand for heat.

Protection of boiler – Boiler protection are provide to detect the abnormal

condition by constantly measuring the various parameter under normal and
faulty condition. If any abnormality happened trip the boiler to prevent
from major damage.

Need of Interlocks & Protection

◦ To avoid operational faults
◦ To avoid equipments damage.
◦ To avoid accidents to individuals.
◦ To avoid system disturbances
Master Fuel Trip - it produces trip signal for fuel systems from operation , then trip the boiler
out of service away from danger. this relay needs many conditions to operate , these conditions
will be found at the following points.
 1. Both ID fan trip. • 9. Unit flame failure.
 2. Both FD fans trip. • 10. Loss of fuel.
 3. Emergency manual trip. • 11. Loss of scanner cooling air (Scanner air
 4. Turbine tripped and HPLP bypass pressure<2 KPa with 5 min time delay).
not opened (RH protection act). • 12. Both APH tripped.
 5. Drum level low low low (<-325mm • 13. Oil burner light off failed.
with 5 sec delay).
 6. Total air flow<30%.
• Other than MFT-
 7. Furnace pressure low low low (<-254
• 1. MS temperature≥5850C (5 sec time
mm of H2O). delay).
 8. Furnace pressure high high high
• 2. RH temperature≥5850C (5 sec time
(>+330 mm of H2O).
delay).
 Interlocks cum protections

 1. If one ID fan trips, one FD fan will trip in the same sequence.
 2. If one FD fan trips, one ID fan will trip in the same sequence.
 3. If one APH trips, one ID fan, one FD fan and one PA fan will trip in the same sequence.
 4. In case of GCB opening, top elevation mill or non adjacent mill will trip.
 5. If drum level≥200 mm, EBD will open.
 6. If drum level≤150 mm, EBD will close.
 7. Feed water flow<50 TPH, Economiser recirculation MOV will open.
 8. Feed water flow>80 TPH, Economiser recirculation MOV will close.
 9. If superheated steam pressure is higher than 14.86 MPa ERV will open and if pressure is
lower than the value ERV will close (if kept in service).
 1. Boiler drum pressure-
 a) Higher than 17.24 MPa LHS safety valve will lift and it will reset @ 16.35 MPa.
 b) Higher than 16.74 MPa RHS safety valve will lift and it will reset @ 16.21 MPa.

 2. Superheated steam pressure-

 a) Higher than 15.29 MPa, LHS safety valve will lift and it will reset @ 14.765 MPa.
 b) Higher than 15.2 MPa, RHS safety valve will lift and it will reset @ 14.747 MPa.

 3. CRH steam pressure-

 a) Higher than 3.058 MPa, LHS safety valve will lift and it will reset @ 2.947 MPa.
 b) Higher than 2.963 MPa, RHS safety valve will lift and it will reset @ 2.867 MPa.

 4. HRH steam pressure-

 a) Higher than 2.817 MPa, LHS safety valve will lift and it will reset @ 2.726 MPa.
 b) Higher than 2.75 MPa, RHS safety valve will lift and it will reset @ 2. 62 MPa.
 Drum level
 1. Level>125 mm: high priority alarm.
 2. Level>-125 mm: high priority alarm.
 3. Level>250 mm: emergency priority alarm.
 4. Level>-250 mm: emergency priority alarm.
 Furnace pressure
 1. Pressure>30 mm of H2O: high priority
alarm.
 2. Pressure>-30 mm of H2O: high priority
alarm.
 3. Pressure>50 mm of H2O: emergency
priority alarm.
 4. Pressure>-50 mm of H2O: emergency
priority alarm.
 MS flow
 1. MS flow>200 TPH: high priority alarm.
 2. MS flow>450 TPH: emergency priority
alarm.
• MS & RH Temperature
• 1. MS temperature>5450C: high priority alarm.
• 2. MS temperature>5500C: emergency priority
alarm.
• 3. RH temperature>5450C: high priority alarm.
• 4. RH temperature>5500C: emergency priority
alarm.
• Others
• 1. APH flue gas inlet temperature<3000C: high
priority alarm.
• 2. O2<1: high priority alarm.
• 3. O2 zero: emergency priority alarm.
• 4. Furnace DP≥90 mm of H2O: high priority
alarm.
• 5. Furnace DP≤10 mm of H2O: high priority
alarm.
 1. No ID fan A/B converter/ device fault.
 2. No ID fan protection acted.
AND Start enable
 3. ID fan A/B inlet & outlet damper closed. Interlock:
 4. ID fan IGV in minimum position.
 5. APH A/B flue gas inlet & outlet damper open.
 6. APH A/B running

 1. ID fan A/B breaker protection acted. Or

 2. BMS trip ID fan A/B. Or
 3. FD fan A/B tripped. Or TRIP enable
 4. APH A/B tripped. Or OR Interlock:
 5. ID fan A/B temperature protection acted.
 6. ID fan A/B vibration protection acted.
 7. ID fan A/B running and fan outlet damper closed.
 ALARM
 1. Fan/ motor bearing temperature≥750C: high priority alarm.
 2. Fan/ motor bearing temperature≥800C: emergency priority alarm.
 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm.
 4. Fan bearing vibration≥11mm/sec: emergency priority alarm.
 5. Motor winding temperature≥1100C: high priority alarm.
 6. Motor winding temperature≥1200C: emergency priority alarm
TRIP
 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60sec time
delay).
 2. Fan/ motor bearing temperature≥900C (with 60 sec time delay).
 3. Fan bearing vibration≥11mm/sec ( with 60 sec time delay).
 4. ID fan motor protection (over current, earth fault, negative sequence, phase fault
etc) acted.
 5. BMS trip ID fan.
 6. FD fan trip to ID fan trip.
 7. ID fan running and fan discharge damper closed.
 8. APH trip to ID fan trip.
 1. No FD fan A/B converter/ device fault.
 2. No FD fan protection acted.
 3. FD fan A/B outlet damper closed. Start enable
 4. FD fan IGV in minimum position.  AND Interlock:
 5. APH A/B flue gas inlet & outlet damper open.
 6. APH A/B running.
 7. ID fan A/B running.

 1. FD fan A/B breaker protection acted. Or

 2. BMS trip FD fan A/B. Or
TRIP enable
 3. ID fan A/B tripped. Or  OR Interlock:
 4. APH A/B tripped. Or
 5. FD fan A/B temperature protection acted.
 6. FD fan A/B vibration protection acted.
 7. FD fan A/B running and fan outlet damper closed.
 ALARM
 1. Fan/ motor bearing temperature≥750C: high priority alarm.
 2. Fan/ motor bearing temperature≥800C: emergency priority alarm.
 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm.
 4. Fan bearing vibration≥11mm/sec: emergency priority alarm.
 5. Motor winding temperature≥1100C: high priority alarm.
 6. Motor winding temperature≥1200C: emergency priority alarm.
TRIP
 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60sec time delay).
2. Fan/ motor bearing temperature≥900C with 60 sec time delay.
3. Fan bearing vibration≥11mm/sec with 60 sec time delay.
4. FD fan motor protection (over current, earth fault, negative sequence, phase fault etc) acted.
5. BMS trip FD fan.
6. ID fan trip to FD fan trip.
7. FD fan running and fan discharge damper closed
 1. No PA fan A/B converter/ device fault.
 2. No PA fan protection acted.
 3. PA fan A/B outlet damper closed. Start enable
 4. PA fan IGV in minimum position. AND Interlock
 5. APH A/B flue gas inlet & outlet damper open.
 6. APH A/B running.
 7. ID fan A/B running.
 8. FD fan A/B running.
 9. No boiler trip command.

 1. PA fan A/B breaker protection acted. Or

 2. MFT trip PA fan A/B. Or
 3. ID fan A/B tripped. Or
Trip enable
 4. FD A/B tripped. Or • OR Interlock:
 5. PA fan A/B temperature protection acted.
 6. PA fan A/B vibration protection acted.
 7. PA fan A/B running and fan outlet damper closed
  ALARM
 1. Fan/ motor bearing temperature≥750C: high priority alarm.
 2. Fan/ motor bearing temperature≥800C: emergency priority alarm.
 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm.
 4. Fan bearing vibration≥11mm/sec: emergency priority alarm.
 5. Motor winding temperature≥1100C: high priority alarm.
 6. Motor winding temperature≥1200C: emergency priority alarm.

 TRIP
 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60 sec time delay).
 2. Fan/ motor bearing temperature≥900C with 60 sec time delay.
 3. Fan bearing vibration≥11mm/sec with 60 sec time delay.
 4. PA fan motor protection (over current, earth fault, negative sequence, phase fault etc)
acted.
 5. MFT trip PA fan.
 6. ID fan/ FD fan A/B trip to PA fan A/B trip.
 7. PA fan running and fan discharge damper closed.
 1. No fan converter/ device/ breaker fault.
 2. Any one PA fan running.
 3. Fan IGV in minimum position.
 4. In case of one fan running & other fan standby-
 a) If running fan getting tripped due to any protection acting Start enable
• AND interlock
then stand by fan will start in interlock if selected.
 b) If seal air pressure becomes low (<6 KPa), then standby fan
will start by interlock.
 4. During unit start up fan start enable will come with the start
of any PA fan if selected in fan auto start interlock.
 **Command will go to Seal air fan IGV for 60% opening in auto
with the start of the fan.

 1. Fan breaker protection acted. Or

 2. Both PA fans are stopped (after 2S fan will stop).or  Trip enable
• OR
 3. In case of both seal air fan running and seal air header interlock:
pressure>22 KPa then one seal air fan will stop in auto if selected
in interlock (discharge pressure
 1. Seal air fan current>200 Amp: high priority
alarm.
 2. Seal air fan current>260 Amp: emergency
ALARM
priority alarm.
 3. Seal air discharge pressure<800: high priority
alarm.
 4. Seal air discharge pressure<600: emergency
priority alarm.

 1. Seal air fan current≥ 284Amp.

 2. Both PA fans stopped/ tripped (fan trip after
2Sec). TRIP
 3. Seal air fan breaker protection acted.
 4. Seal air header pressure>22 KPa (in case of both
fans are running), trip one fan.

 1. No motor or breaker protection acted.
 2. Fan is in remote.
 3. In case of one fan is running and the other is in Start Enable
stopped condition- AND Interlock
 a) By interlock input if one fan is stopped/ tripped,
standby fan will start in auto.
 b) If scanner air header pressure<2 KPa for 5 sec, then
standby fan will start in auto by interlock input.

 1. Scanner air header pressure< low switch acting:

emergency priority alarm. Alarm
 2. Scanner air fan trip: emergency priority alarm.

 1. Scanner air fan breaker protection acted. Trip

 2. Scanner air fan motor protection acted.
 1. No breaker/ motor protection acted.
 2. Lube oil pressure normal for > 5 minutes.
 3. No MFT acted.
 4. Boiler drum pressure>3.4 kg/cm2.
 5. Secondary air temperature>1770C. Start Enable
AND Interlock
 6. Total air flow<40% (230TPH).
 7. MDVs are open.
 8. Mill outlet temperature<1150C.
 9. Cold air gate is open.
 10. Coal feeder is in remote.
 11. PA permit satisfied.
 12. Mill ignition permit satisfied.
 1. Feeder trip and no mill ignition permit.
 2. MFT.
 3. MDVs closed.
 4. Lube oil pressure low (2 out of 3 lube oil pressure<low AND TRIP Enable
switch act). Interlock
 5. Seal air differential pressure low low.
 6. Loss of primary air (differential pressure between APH
outlet primary air and furnace pressure less than 460mm
of H2O.

 Other Interlocks:
 1. On tripping of mill Close command will go to HAG.
 2. In case of GCB opening and unit coming to house load,
top/ non adjacent mill will trip.
 3. In case of one ID fan tripping, one top elevation mill
will trip.
 1. Mill lube/ hydraulic oil tank temperature>750C: high priority
alarm.
 2. Mill lube oil thrust pad oil temperature>600C: high priority alarm.
 3. Mill lube oil thrust pad oil temperature>700C: emergency priority
alarm.
 4. Mill motor front/ rear bearing temperature>750C: high priority
alarm. Alarm
 4. Mill motor winding temperature>1000C: high priority alarm.
 5. Mill outlet, roller bearing temperature>900C: high priority alarm.
 6. Mill current>60 amp: high priority alarm.
 7. Mill inlet PA flow< 50 TPH: high priority alarm.
 8. Mill hydraulic pressure>150 kg/cm2: high priority alarm.
 9. Mill hydraulic pressure<70 kg/cm2: high priority alarm.
 10. Seal air header pressure<800 mm of H2O: high priority alarm.
 11. Seal air header pressure<600 mm of H2O: emergency priority
alarm.
 1. Mill motor protection (over current, earth fault, negative
sequence, phase fault etc) acted.
 2. MFT trip mills.
 3. MDVs closed trip mill (2 out of 4 MDVs).
 4. Mill lube oil pressure low (2 out of lube oil pressure<low switch
acting) trip mill.
 5. Loss of primary air (differential pressure between APH outlet
primary air and furnace pressure less than 460mm of H2O).
 6. Feeder trip and no mill ignition permit.
 7. Seal air differential pressure low low.
 8. Mill lube oil pump in local.
 OTHERS
 1. In case of GCB opening and unit coming to house load, top/ non
adjacent mill will trip.
 2. In case of one ID fan tripping, one top elevation mill will trip.
 Start enable Interlock:
 1. No breaker or motor protection acted.
 2. Respective mill ignition permit.
Start Enable
 3. Feeder speed (VFD command) minimum. AND Interlock
 4. No mill trip command.
 5. Feeder is in remote.

 1. Mill trip/ emergency stop.

 2. MFT. Stop/Trip
OR
Enable
 3. Feeder running and no coal.
Interlock:
 4. Mill outlet temperature<540C and HAG closed and
feeder VFD command<2%.
 1. Belt deviation of feeder switch act: high priority alarm.
 2. No coal switch act: high priority alarm.
 3. Coal jam switch act: low priority alarm. Alarm
 4. Feeder cleaner motor fault: low priority alarm.
 5. Coal flow zero: low priority alarm.

 1. Mill trip to feeder trip.

 2. MFT to feeder trip.
Trip
 3. Feeder motor/ breaker protection acted.
 4. Feeder running and no coal.
 5. Mill outlet temperature<540C and HAG closed and feeder VFD
command<2%.
 Mill Lub Oil Pump Interlock & Protection

 1. No breaker or motor protection acted.

 2. LOP is in remote. Start enable
AND
 3. Oil pool temperature of lube oil>600C. Interlock

 1. Oil pool temperature of lube oil<450C.

Stop/trip
 2. After LOP starting if oil pool OR enable
temperature of lube oil<450C and mill not Interlock
running (30 mins time delay).
 3. After mill stopping after 4 hrs time
delay stop command will go for LOP.
 1. Lube oil pump stopped: emergency priority alarm.
 2. Lube oil pressure<low switch act: emergency priority
alarm.
Alarm
 3. Oil pool temperature>: 750C high priority alarm.
 4. Lube oil thrust liner sump temperature>: 600C high
priority alarm.
 5. Lube oil thrust liner sump temperature>: 700C emergency
priority alarm.

 1. LOP motor/ breaker protection acted.

 2. Oil pool temperature of lube oil<450C.
 3. After LOP starting if oil pool temperature of lube oil<450C Trip
and mill not running (30 mins time delay).
 4. After mill stopping after 4 hrs time delay stop command
will go to LOP.
  1. No breaker or motor protection acted.
 2. APH is in remote. Start enable
 3. Guide and support bearing oil pump running for minimum of 300 sec
AND Interlock
(for U#2 APH).

 1. APH flue gas inlet temperature<800C and fans (ID, FD & PA) are
running.
Stop/trip
 2. For APH auxiliary motor, with the start of APH main motor trip OR enable
command will go. Interlock:

• Other Interlocks:
• 1. Start command will go for APH auxiliary motor (DC) with the tripping of APH main motor.
• 2. In case of APH main motor VFD getting bypassed due to any fault, APH main motor DOL supply will
pick up.
• 3. For U#2 APH-
• a) If APH support/guide bearing temperature> 540C, lube oil pump will start.
• b) If APH support/guide bearing temperature< 500C, lube oil pump will stop