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Bharat Heavy Elelctricals Limited: Operation & Maintenance Manual of Bhelscan Flame Scanner System (Bn10)
Bharat Heavy Elelctricals Limited: Operation & Maintenance Manual of Bhelscan Flame Scanner System (Bn10)
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BHELSCAN O & M MANUAL
CONTENTS
Section 1 INTRODUCTION
Section 2 SYSTEM SPECIFICATION
Section 3 MECHANICAL COMPONENTS
Section 4 COOLING AIR REQUIREMENTS
Section 5 ELECTRICAL COMPONENTS
Section 6 DESCRIPTION OF MODULES
Section 6.1 FLAME PROCESSOR MODULE
Section 6.2 2/4 OUTPUT MODULE
Section 6.3 POWER SUPPLY MODULE
Section 6.4 SCANNER HEAD ELECTRONICS
Section 7 COMMUNICATION INTERFACE
Section 8 INSTALLATION AND START UP PROCEDURES
Section 8.1 MECHANICAL COMPONENTS
Section 8.2 COOLING AIR
Section 8.3 ELECTRICAL COMPONENTS
Section 8.4 SYSTEM OPERATION TEST
Section 8.5 DIP SWITCH SETTING PROCEDURES
Section 8.6 CALIBRATION OF SCANNER HEAD ELECTRONICS
Section 9 FLAME SCANNER CABLE
Section10 MAINTENANCE & TROUBLESHOOTING
Section 10.1 SCANNER HEAD
Section 10.2 FIBRE OPTIC CABLE
Section 10.3 ELECTRICAL COMPONENTS
Section 11 LIST OF FIGURES
LIST OF FIGURES:
Figure-1 : Windbox arrangement showing Flame scanner system
Figure-2 : Flame Scanner Guide pipe assembly
Figure-3 : Flame scanner assembly with optical head
Figure-4 : Collimeter lens with barrel assembly
Figure-5 : Functional block diagram
Figure-6A : BHELSCAN - General arrangement
Figure-6B : BHELSCAN - General arrangement
Figure-6C : Schematic of processor motherboard
Figure-7A : Block diagram of Flame processor
Figure-7B : BHELSCAN – Flame processor module
Figure-8A : Block diagram of 2/4 output module
Figure-8B : BHELSCAN – 2/4 module
Figure-9A : Block diagram of power supply
Figure-9B : BHELSCAN – Power supply module (Front view)
Figure-9C : BHELSCAN – Power supply module (Rear view)
Figure-9D : Schematic of power supply motherboard
Figure-10 : Block diagram of Scanner Head electronic module
Figure-11A : Flame scanner interconnection diagram
Figure-11B : TB wiring details (Front mounted TB version)
Figure-11C : TB wiring details (Rear mounted TB version)
Figure-11D : BHELSCAN – TB arrangement (Rear mounting)
Section 1 – INTRODUCTION
The prime output of flame sensing
The microcontroller based flame system is called the “two out of four flame
sensing system is designed primarily for ON” for coal, when two or more than two
use on coal fireball and stable oil flame coal flame in an elevation is detected and
ignited by high energy arc (HEA) ignitor. It “individual flame ON” for oil. The output is
senses the visible light given off by the represented by the positioning of a set of
flame and can recognize a coal/oil flame by form C contacts (break before make). A
its characteristic fluctuations. current signal is also available to indicate
the individual flame intensity corresponding
The system consists of a fibre-optic to each corner. RS232C serial output is
connected scanner head assembly and a available for computer/DCS connectivity.
chassis containing electronic signal
processing modules. The scanner head
assy. is located at the boiler and the
chassis with electronics is mounted in the
control room. The chassis may be located
up to 200 metre from the boiler. A shielded
four-conductor cable sends power to the
scanner head electronics and returns an
electronic signal representing flame to the
chassis.
Specifications
Input signal : 0 to 2mA AC from Head BHELSCAN comes in two versions - one
Electronics with terminal blocks for field
Processor Modules for 1 elevation with terminal blocks fitted in the back
2/4 Processor : 2/4 logic detection & fault side. Version with TB fitted in the front is
Programmable : Pull in, Pull out, BHELSCAN rack assemblies fitted has
Parameters Flicker frequency for oil, only front doors and no back doors
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BHELSCAN O & M MANUAL
NOTE
A wind box structure will sometimes 3. Lock the mounting plate to the lens
restrict the location of the guide pipe barrel with the jam nut.
scanner head housing. To permit the 4. Insert the lens barrel in the scanner
scanner to see the flame, a prism may head body until the mounting plate
be installed in place of the collimator rests against the stop pins.
shield. Use care when placing the 5. Insert the compression spring and
scanner in the guide pipe to assure plug. Three socket head screws hold
proper orientation of the scanner head the plug in the scanner head body.
assembly.
2. Thread the fibre-optic cable, which is
normally coiled inside the scanner
housing assembly, through the rigid
pipe, flex metal hose and the scanner
head body plug. Make sure the jam
nut is in place on the cable before
installing the compression spring and
mounting plate. Then screw the
collimating lens barrel onto the cable.
The external cooling air passes temperature measured at the scanner air
through the guide pipe, the flexible hose booster fan inlet). Air manifold pressure at
and the annulus between the scanner head the scanner guide pipe must be
and housing. The air is discharged into the 150mmwc.(g). above furnace pressure for
furnace at the top of the scanner head, all operating conditions. After shutting
thereby removing any heat picked up by down the unit, scanner cooling air must be
the scanner from the hot combustion air. maintained until furnace conditions are
The scanner head should not be exposed such that the scanner assembly cannot
to a continuous temperature above 300°F overheat. Shut off valves must not be
without cooling air. installed in cooling air lines to the
scanners.
NOTE
When the scanner assembly
housing adapter flange is disconnected,
the scanner assembly must be removed
from the guide pipe immediately. Wrap
a cloth around the scanner support pipe
and hold it firmly against the cooling air
manifold to minimize the escape of
cooling air while the head is being
removed. The head should then be held
in the rag to protect it from damage.
Install the cover plate to retain the
cooling air flow within the scanner
guide pipe. This prevents a reduction of
cooling air pressure at the remaining
scanners.
Cooling air flow requirements are
(per scanner) 55 cfm at 120°F (maximum
will come along with the system fault LED changeover contact output for system fault.
and that channels flame output will be Description of the various modules are
disabled. The 2/4 module gives 2 given in the following sections:
changeover contacts for 2/4 flame and one
The flame scanner card rack assembly putting into its slots. The scanner head
consists of the following modules: current signal (0 – 2.0 mA) enters flame
1. Flame processor - 4 Nos. processor module and is converted to
module voltage. The voltage is signal is normalized
2. 2/4 output module - 1 No. in signal conditioner such that, a high
3. Power supply unit - 1 No. voltage represents the bright furnace and
Refer BHELSCAN general arrangement low voltage represents the dark furnace.
drawing. ( Figure – 6A & 6B )
This signal is divided into three
The flame processor modules and 2/4 parts. One signal goes to intensity
output module are mounted in processor monitoring circuit. This consists of a
motherboard, assembled in the card rack. voltage amplifier and an ADC. The output
Refer Schematic diagram of Processor of this ADC is connected to Microcontroller.
mother board.( Figure – 6C ) The power
supply unit is mounted in the power supply The second and third signals are
motherboard, assembled in the card rack. fed to frequency detection circuit. This
circuit consists of an AC amplifier and a
wave shaper. One output represents the
6.1 Flame Processor Module
coal flame fluctuation and the other output
represents the oil flame fluctuation. The
(Refer block diagram – Figure - 7A &
outputs are fed to microcontroller. The AC
7B) : gain can be adjusted to suit the furnace
This module is a standard euro card flame condition independently for coal and
suitable for 19” rack assembly. Flame oil flame flicker levels by RP1 and RP6
processor module is located in the slots 1 single turn potentiometers respectively.
to 4 in the processor module. These
modules can be interchanged within them. The +/-15 V DC and GND are
The set values can be verified before extended to scanner head electronics
located at furnace front in the field from this and energies the relay. Also, the status of
module. There are two semiconductor flame1 and flame 2 and fault are
fuses rated for 63mA are available in the transferred to the 2/4 output module. The
flame processor motherboard to protect the microcontroller updates the display and
DC supply to scanner head electronics. LED status according to the input.
The removal of this module blocks the DC The digital outputs of flame1 (coal)
supply to field. and flame2 (oil) status are fed to the 2/4
DO NOT REMOVE ANY MODULE WITH output module. A 4-20 mA current output is
POWER ON available to represents the intensity of the
There are 4 DIP switches (each flame. This circuit consists of a DAC and
switch with 8 bits) are available to set the current converter.
following data in binary form to the
microcontroller. For DIP switch settings, Relay outputs are available in form
refer DIP SWITCH SETTING of change over contact for flame 2(oil)
PROCEDURE. output to use in BMS of boiler. For the
a. Pull in value (typical value is 40%) location of DIP switches and AC gain
b. Pull out value (typical value is 30%) potentiometers, refer Figure - 7B.
c. Coal frequency set value
(typical value is 5 Hz. ∗)
6.2 2/4 Output Module
d. Oil frequency set value
(typical value is 30 Hz. ∗)
(Refer block diagram – Figure – 8A &
∗ - Adjustable at site.
The front facia of this module 8B ) :
consists of a 7-segment display, 9 status This card is a standard euro card
LEDs and one Push Button. Card pullers suitable for 19” rack assembly. This is
are available to remove the card from the located in the 5th slot of processor
rack. A mode PB can change the display motherboard. The heart of the module is
mode to scroll the various values. an 8-bit microcontroller. This receives
digital signals corresponding to flame1 ON
The heart of the system is an 8-bit from all four flame processor modules.
microcontroller. This receives the signals Whenever, two or more than two flame 1
from ADC, wave shaping circuit, mode PB (coal) inputs are available, this module
and DIPswitches. From these signals, the gives output for 2/4 flame ON output. This
microcontroller decides the flame status indicates the presence of fireball. There
are two relays available. One relay is for power supply motherboard to switch ON
the 2/4 output of coal flame. The other the AC power supply to this module. In the
relay is for fault alarm to DCS. RS232C front facia, four status LEDs are available
serial communication circuit, transfer the for presence of AC power ON, -15V DC
flame parameters for all processor ON, +15V DC ON and +5 V DC ON. All
modules to computer on-line via serial port. four LEDs should glow for the normal
Two sets of 2/4 output relay contacts are operation of flame scanner.
available at the terminal. These are
changeover contacts. In the front facia, two
6.4 Scanner Head Electronics
status LEDs are available for 2/4 output
indication and fault status. Refer Figure –
(Refer figure – 10 ) :
8B for the location of 2/4 relay (Fireball
flame ) and fault relay.
This is a circular module available
inside the flame scanner head assembly.
6.3 Power Supply Module This is mounted at furnace front in the
windbox. A special triple shielded flame
(Refer Figures - 9A, 9B, 9C & 9D ) : scanner cable connects this module to
respective flame processor module in the
This is a linear power supply flame scanner card assembly at flame
suitable for 19” rack assembly. This is scanner panel located at remote control
mounted in power supply motherboard. room.
This will work in 110V AC or 230V AC as This module converts the light
given in the nameplate. This is factory set. transmitted from the furnace flame. (via a
There are three DC outputs produced in fibre optic cable) to an electrical signal.
this module. Visible light from the flame strikes photo
1. +15 V DC @ 0.75 Amps maximum diode and is converted into a current
2. –15V DC @ 0.25 Amps maximum signal. This current is linear function of
3. +5.0V DC @ 1.5 Amps maximum illumination (intensity) and covers five-
All the above DC outputs are over decade range of lux. Photo diode signal is
voltage and short circuit protected. There is converted to log signal voltage in the
a fuse available in the power supply temperature log amplifier to cover the
motherboard, whose rating is 2 Amps. A entire range of intensity. Amplifier offset
DPDT toggle switch is provided in the and gain adjustments are factory set
through potentiometers R101, R103. This or dark furnace conditions. This feedback
voltage signal is converted to current signal loop is the key circuit in the electronic fault
(0 – 2.0 mA) for transmission to flame detection scheme. The light emitted by the
processor module. feedback LED is adjusted by R114
A feedback LED is mounted in the potentiometer during calibration at
photo diode holder, to avoid the saturation laboratory / factory.
of log amplifier in the event of very low light
FLAME SCANNER
CORNER1 CORNER2 CORNER3 CORNER4
Actual Intensity
Pull in set
Pull out set
Frequency 1 set
Frequency 2 set
Actual frequency 1
Actual frequency 2
Flame 1
Flame 2
The above table will be updated automatically every second approximately.
Make sure the Safe Scan head assembly withdraw the scanner from the guide pipe
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BHELSCAN O & M MANUAL
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BHELSCAN O & M MANUAL
13. During boiler operation, the “Flame1” e. Oil frequency is less than F2 set value
LED in respective corner processor OR
module will be ON when the following f. Any fault conditions exits. (Fault LED
conditions are met. ON)
a. Flame intensity is more than PI set 15. 4-20 mA current output is available
value AND corresponding to 0 – 100% of flame
b. Coal frequency is more than F1 set intensity in respective corner at TB
value AND Nos. 9 & 10. If any fault condition
c. No Fault condition exists (Fault LED exists, (Fault LED ON), this current
OFF) output will go to 4 mA irrespective of
Flame1 LED will switch OFF, if any the intensity level shown in display.
one of the following conditions is met. 16. The 2/4 Flame LED indication in 2/4
a. Flame intensity is less than PO set flame module represents the presence
value OR of fireball during coal firing. This LED
b. Coal frequency is less than F1 set will be ON, whenever, two or more
value OR corner’s “Flame1” (coal flame) show
c. Any fault conditions exits. (Fault LED flame. The relay outputs in two sets of
ON) contacts are available at TB Nos.1,2&3
14. During boiler operation with oil, the and 4,5 & 6 of TB5.
“Flame2” LED will be ON when the 17. If any fault LED is ON in any of the
following conditions are met. The processor modules, Fault LED in 2/4
relay output is available at TB Nos. module will be ON. The Fault relay will
6,7 & 8 in the respective corner. get energized. The relay output is
a. Flame intensity is more than PI set available in TB Nos. 7&8 of TB5.
value AND 18. RS232-C serial communication output
b. Oil frequency is more than F2 set is available at TB Nos.10, 11 & 12 in
value AND TB5. This can be used to communicate
c. No fault condition exists. (Fault LED the flame parameters to Personal
OFF) Computer.
Flame2 LED will switch OFF, if any
one of the following conditions is met.
d. Flame intensity is less than PO set
value OR
(Refer Figure – 7B ) :
Switch OFF the power supply to BHELSCAN system. Remove the flame processor
module at corner 1.
Locate S1 DIP switch as shown in Figure – 7B for intensity pull-in value. Set ‘40’ by
keeping the individual switch as below.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF OFF ON OFF ON OFF OFF OFF
Locate S2 DIP switch as shown in Figure – 7B for intensity pull-out value. Set ‘30’ by
keeping the individual switch as below.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF OFF OFF ON ON ON ON OFF
Locate S3 DIP switch as shown in Figure – 7B for coal frequency set value. Set ‘05’ by
keeping the individual switch as below.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF OFF OFF OFF OFF ON OFF ON
Locate S4 DIP switch as shown in Figure – 7B for oil frequency set value. Set ‘30’ by
keeping the individual switch as below.
DIP switch position: 8 7 6 5 4 3 2 1
Setting status OFF OFF OFF ON ON ON ON OFF
For other values of above settings, convert the decimal value to 8 bit binary and set
the DIP switches accordingly. For ‘1’ status, the switch shall be in ON position.
Repeat the same procedure for settings in other flame processor modules. Insert
the modules into the respective location and switch ON the AC power supply. Verify the
set values in individual flame processor module by selecting the display using mode PB.
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BHELSCAN O & M MANUAL
Connect a digital voltmeter (DVM) between approximately 2.1V. This completes the
the signal C and common D terminals on scanner head electronics adjustments.
the electronics card. Disconnect the test leads, reassemble the
scanner assembly and reinsert it in the
Reconnect the scanner cable to the guide pipe.
scanner assembly. The power supply All four scanner channels, under dark
switch should be turned on. Work under a furnace conditions, should have a similar
dark cloth to reduce he amount of ambient intensity meter reading.
light admitted to the scanner head. Adjust
potentiometer P114 so that the DVM reads
opening for viewing the flame. With does occur, the best way to troubleshoot
certain types of coal, slag may eventually the system is to substitute modules in the
build up and cover the opening. The card rack assembly and/or head
periodically and cleaned, if necessary. inserted only in the slots designated for
flame scanner cable connection between vanish. If this fault persists even then,
the terminal block and the head 2/4 flame module may need replacement.
electronics in the field. If continuity is
also alright, then head electronics may Do not insert or pull out any
need recalibration or replacement. For module from the connector when power
any other fault in this module like no is ON. This may damage the module. If
response for mode selection PB, any module has to be removed for