FSSS 330MW

Mr.Anjan Dastidar
Mr.Amit Pandey
FSSS ?
 F : Furnace
 S : Safeguard
 S : Supervision
 S : System
 FSSS : Furnace Safeguard Supervision
System
Why FSSS ?
 FSSS can prevent the mix of explosive fuel and air from accumulating
anywhere inside a boiler, thus avoiding accidents such as boiler explosion
and ensuring the operational safety of boiler.

 FSSS system will offer furnace purging judgment logic and ignition mode in
conformity to the safety regulations to operators for the start and
operation of boiler.

 FSSS system monitors and supervises carefully work conditions relating to

boiler safety during normal operation of boiler, including furnace flame,
furnace pressure, blower, induced draft fan, steam drum water level, fuel
provision, etc.

 The operators may be informed on the work conditions for the operational
safety of boiler directly in engineer station. FSSS system will warn the
operators in case of abnormity to such information. It may also send MFT
tripping instruction, if necessary conditions are true, to cut off fuel, serving
as a reliable technological guarantee to boiler operational safety.
 List of Boiler Main Equipment
 Two forced draft fans (FDF)
 Three primary air fans (PAF)
 Three induced draft fans (IDF)
 Two sealing air fans
 Two air preheaters
 Two electrostatic precipitators
 Five Coal Mills
 Two Scanner Air Fan
 Burner System
 System Functions
 FD FAN Supplies heated air (Secondary Air) to the Boiler Furnace
in the amount and at the temperature required for optimum
combustion of coal.
 PA FAN Supplies heated air (Primary Air) to the Pulverizing Mill for
drying coal during the pulverizing process and conveying pulverized
coal into separators.
 Seal Air Fan Provides seal air for the coal feeders, the pulverizers
and the dampers
 ID fan removes the furnace combustion gases, through flue gas
duct, electrostatic precipitator,chimney to the atmosphere.
 Electrostatic Precipitators collects & removes the Ash (Dust)
mixed inside the flue gas.
 Coal Mill are system where coal is grinded & dried. Coal with
required fineness is produced.
 Scanner Air Fan are used for providing cooling air to Oil & Coal
Flame scanners.
Burner System
 There are totally 20 sets of oil gun equipped in each boiler.
 The oil gun has to be put into operation to support the ignition and
stable combustion during the startup and shutdown of the pulverizer, as
well as during lower load condition
 The function of burner is to setup a stable ignition at the appropriate
range beyond the burner nozzle, and achieve the complete combustion.
 Each Burner has two SA zones from where Secondary air from FD fan
is introduced inside the zone.SA zone is equipped with adjustable
vanes located in each zone which can enhance the ignition.
 Each burner will be equipped with a set of High-Energy Spark Ignition
system(2.5kv) to ignite the fuel automatically. This igniter consists of HE
transformer, ignition rod, ignition cable, spark, oil gun and retractable
cylinder.
 Burner also has Oil valve & purge valve. Oil valves are used to provide
ignition oil i.e LDO & Purge valve are used for purging of the oil lines
with help of compressed air.
FSSS - Furnace Safeguard
Supervision System
 Boiler MFT (Master Fuel Trip)
 Boiler OFT (Oil Fuel trip)
 Furnace Purge Conditions
 Boiler RB(Runback)
 Oil Level Permission
 Coal Level Permission
 Oil Gun Control
 Purge Conditions
Purge time : 300 seconds
 All PA fan stopped

 Supply oil valve closed

 All corner valve closed

 All mills stopped

 All coal feeders stopped

 Any ID/FD Fan running

 Total air >30% (300TPH)

 Furnace pressure normal

 Drum level normal

 No MFT

 Both APH running

 ALL scanner no flame

 No Leak test

 Auxiliary air dampers at purge site(50 % Open)

PURGE LOGIC
OIL LEAK TEST
 Leak test goal: Checking the tight shutoff of oil valves.
 Leak test method: When open and close oil supply or return valve,
using oil pipe pressure signal to judge whether the oil pipe and oil
valve is leaking or passing.
 The choice of leak test: According to the operator need, before the
boiler ignition, select the leak test or may choose the bypass. If
select the bypass, then the leak test indicating lamp to be bright, the
system does not need after the divulging testing then to carry on the
next step the operation. If select leak test on successful completion
of the leak test , spark permitted for lit up.
The leak test process is as follows:
 Press the start leak test button provided in operator screen.

 After the leak test turns ON, the oil supply and return valve shall open .

 Then closed oil return valve and check leak test oil- pressure (2.8 Mpa)
satisfies appropriately. If the pressure does not develop upto 2.8 Mpa
then send the oil leak test fail signal. The leak test is fail and the
program is stop.

 Close the supply valve and wait for 180 seconds If the oil pressure
satisfies acceptable limit of 2.55 Mpa then move to next step and if it
does not remain within acceptable limit of 2.55Mpa for 3 minutes .
Then it is considered as leak test fail.
 If the leak test oil pressure acceptable signal is maintained for 3
minutes, open the return valve and the control valve. After 30
seconds, judge the differential pressure (0.5 Mpa) oil supply force
and after is recovery. If the different pressure is recovered, the leak
test is fail. If the different pressure is not recovered, next step.

 Close return oil valve and control valve. After 3 minutes, judge the
different pressure (1.5 Mpa) oil supply force and after if recovery. If
the different pressure is recovered, the leak test is fail. If the
different pressure is not recovered the leak test completes.
Causes of Master Fuel Trip (MFT)
 Both FD Fans trips:-

After two FD.F stop, sends this signal. On arriving of stop feedback of both
FD fan with time delay of 1 sec generates MFT.

 All (three) ID Fans trips.

After 3 ID.F stop completely, sends this signal. On arriving of stop feedback of
all three ID fan with time delay of 1 sec generates MFT.

 All (three) PA Fans trips.

System sends this signal after judgment boiler in non-oil layer input when
any mill

running and three PA fan completely stopped.

 Furnace pressure very high(1700 pa) 2out of 3 logic

When two out of three furnace pressure switch is sensed more than set value it
acts and in logic at DCS with a time delay of 2 sec generates MFT.
 Furnace pressure very low(-2500 pa) 2out of 3 logic.
When two out of three furnace pressure switch is acted with a time delay of 2
sec this signal is send for MFT.
 Drum level very high (250mmwc) 2out of 3 logic(delay 5
sec)
Drum water level is measured from level transmitters and if two out of three
level transmitter value crosses the high level then in logic at DCS after 5
second time delay it generates MFT
Drum level very low (-250mmwc) 2out of 3 logic(delay 5 sec)
Drum water level is measured from level transmitter and if two out of three
level transmitter value crosses the low level then in logic at DCS after 5 second
time delay it generates MFT
 Total air flow less than 30% (300 TPH)

Total air flow i.e sum of total primary air flow and secondary air flow is less than
30 % (300 TPH) of total air flow with time delay of 10 sec signal is send to MFT.
 Manual MFT
When operator presses two push buttons at a time given on desk, The system
receives the MFT button trip signal through hard wiring

 Flame Loss :
Arming of Logic: If any mill & Feeder is running for 60 sec logic gets armed.

a. 2/4 coal Flame scanner proven & All Four oil flame scanners of any
elevation not proven generates MFT.

 Critical flame loss:

If nine or more coal flame scanners sensing NO FLAME within time span of 5
seconds this actuates to MFT.

 Fuel loss :
Arming of Logic: After all 4 oil Gun in any is elevation proven.

Main oil supply valve (Trip valve) close or All oil corner valve closed and all Mill
and Feeder stopped .Generates signal to MFT.
FURNACE
FLAME LOSS
FUEL LOSS LOGIC
 Scanner cooling air lost :
Scanner cooling air pressure very low (<3.2 Kpa) two out of three pressure
switches senses cooling air pressure less than set value it acts or both SA
fans are stopped than with time delay of 10 sec sends signal to MFT.

 Ten minute no spark:

After purge completion if any oil gun is not taken in service upto 10 minutes
generates signal to MFT.

 Reheater protection:
Arming :Boiler load > 30 % means MS flow more than 300 TPH OR any Mill &
Federer proven

a. Turbine trips and if HP Bypass valve is not open more than 30 % within
10 sec generates command signal to MFT.

b. When GCB is in OPEN condition and HP Bypass valve has once crossed 30
% open feedback and thereafter closes and attains a feedback of less than
5% open actuates MFT
REHEATER
PROTECTION
 All APH lost:
If Both APH Main and spare motor are stopped for more than 60 seconds the
signal is send to MFT.

 First spark 3 times fail:

After purge end if oil gun burner ignitor sparks failed for three times and oil
flame is not proven then signal is send to MFT.
MFT LOGIC
Causes of Oil Fuel Trip (OFT)
 Manual OFT:
There is one manual OFT button in the operation picture When the situation is
urgent , operator can use this manual OFT button .
 MFT:
When MFT signal is arrived the system on interlock actuates OFT signal

 LDO pressure very low: (<1.5 Mpa)

When fuel oil pressure low low switch two out of three is acted the signal is send
for OFT.

 Supply oil valve closed:

In Normal unit running condition if supply oil valve is closed OFT signal
generated.But the same phenomenon will not generate MFT.
 All corner valve closed:

In Normal unit running condition if all elevation corner oil valve is closed OFT
signal generated.That means during operation of oil gun when the last oil valve
is closed OFT is generated.

 Return oil valve closed:

In Normal unit running condition if return oil valve is closed OFT signal
generated.

 Main & Auxiliary supply fail (230 VAC):

If Main & Auxiliary power supply both are failed OFT signal generated.
OFT LOGIC
Run back to trip Mill
According to CCS the RB action situation is following.

1) One of the running FD fan trip

2) One of the running ID fan trip

3) One of the running PA fan trip

4) One of the running BFP trip

 If any of the above equipment is tripped RB1 signal is generated.

 After RB action, the system only retains three mills running.

 If RB1 action takes place mill cut off is according to E & C sequence ,and
the time interval is 6 seconds. Out of E&C any one mill is in service it shall
extend stop command to the running mill only. No other mill shall get stop
command.
 PAF trip sends out a RB2 signal
If RB2 action, system removes the mill according to E & C
sequence, and the time interval is 6 seconds.
 At the same time, after the RB action, the system shall auto fire oil
gun only in one elevation in Mill A, B,C ,D & E sequential order in a
gap of 60 sec. If in any elevation of oil gun gets proven the
sequence of oil cut in shall stop.
a. For example: if A mill is running, input A oil gun automatically when RB
occurs.
b. If mill A is not running & mill B is running, , input B oil gun automatically
when RB occurs.
c. If the oil gun which will be inputted cannot be inputted automatically in
the scheduled time (60 seconds) . The next oil gun will be inputted .
MILL RUNBACK LOGIC
Oil Gun Permission
 Boiler supply oil pressure not low (>1.5 Mpa)

 Scanner cooling air pressure suitable (>5.6 Kpa)

 No OFT

 Instrument air pressure normal (>0.5 Mpa)

 Total air flow >30%

 Supply and return oil valve open

 Supply oil temperature (> 25 ‘C)

 Purge End
Coal Fire Permission
 Secondary air temperature suitable(>177 .C)

 Total air flow >30% (300TPH)

 No MFT

 Seal air fan running

 PA fan Running

 Seal air fan pressure not low (>13.5 Kpa)

 Primary air pressure suitable (> 7 Kpa)

Oil Burner Control
 This project burner arrangement is front rear wall impacting way.
 Every group has 4 oil gun, each oil gun equipped with scanner, ignitor,
oil valve and purge valve.

 The sequence start control are as follow:

On pressing the start button from operator screen following steps will be
executed in sequence auto mode.
Step-1:- Oil gun advance command is executed and oil gun reaches to its
advance position. After oil gun insert position feedback is
arrived step-2 is executed.
Step-2:- Ignitor advance command is executed and ignitor reaches to its
advance position. After ignitor insert position feedback is
arrived step-3 is executed.
Step-3:- Open the oil valve and ignitor spark command is issued. High
energy ignitor sparking time is 15 seconds. If the flame is
proven, and maintains for 10 seconds, Oil gun ignition is
proven successfully
The sequence stop control sequence is
as follows:
On pressing the Stop button from operator screen following steps
will be executed in sequence auto mode.
1) Step-1:- Close oil valve command is issued to oil valve.Oil valve
gets close and on receiving the close feedback step -2 is
executed.
2) Step-2:- Ignitor advance command issued to ignitor. Ignitor is
advanced and on receiving the advance feedback step-3
is executed
3) Step-3:- Open purge valve and spark command is issued to open
purge valve and spark for 15 seconds.
4) Step-4:- Close purge valve after purge process for 90 seconds,
purge end.
5) Step-5:- Retract oil gun command is issued after purge valve
closed. The sequence stop control finishes.
 The execution time of each step is 10sec,10 sec,100 sec,10sec &
10 sec.
 Mill start permission
 No MFT

 No fast/urgent trip

 Coal level spark permit

 Mill outlet temp (60 -90 ‘C)

 Lube oil system normal (Pump Running & pressure 0.13 Mpa)

 Seal air/Primary Air DP high (> 2 Kpa)

 PA flow >45 TPH

 All mill outlet gates open

 Hydraulic Loading oil pump running

 Mill variable load selected

 Coal feeder stopped

Coal Mill sequence start control
 On pressing the sequence start button in operator screen
following steps will be executed in sequence auto mode.

1) Step-1:- Mill inlet Hot Air & Cold Air valves & dampers close command is
executed and Mill outlet damper and all seal air valve open command is
executed. On receiving the desired feedback of each valves Step-2 is
executed .

2) Step-2:- Start command for lubrication oil pump and hydraulic loading oil is
generated & the fire fighting steam valve is opened for 300 seconds.

3) Step-3:- Mill fire fighting valve close and Coal feeder inlet valve open
command is executed . On receiving the feedback next step is executed

4) Step-4:- Cold air MOV & hot air gate pneumatic cylinder open command is
executed and both valve gets open.
5. Step-5:- Check all below mentioned condition
 Adjust primary air flow more than 45 TPH & outlet temperature within 60-90 ‘C by operating cold
air damper & hot air damper.

 Mill Lube oil condition should be satisfied i.e pressure should be more than 0.1 Mpa.

 Mill hydraulic system should be in variable load condition i.e hydraulic pressure varies with respect
to coal feeding.

 Mill Seal Air to PA DP should be high i.e more than 2 Kpa.

6. Step-6:- Lift roller command is executed and on receiving the lift roller
feedback after 20 seconds next step is executed.

7. Step-7:- Coal Mill start command is generated and on receiving the

feedback next step will be executed.

8. Step-8:- Opens the coal feeder outlet gate and set the coal feeder speed
min value.(12 TPH) Start the coal feeder by giving start command from DCS
after verifying all coal feeder permissive are meet and no trip condition
exists.Fall the roller after the coal feeder running.
Coal Mill stop sequence
On pressing the sequence stop button in operator screen
following steps will be executed in sequence auto mode.
1) Step-1:- Set the coal feeder min 12 TPH and close coal feeder inlet gate
commands are generated. On receiving the feedback next step
2) Step-2:- Coal feeder stop & Feeder outlet damper close command are
executed. After 60 seconds time delay next step is executed
3) Step-3:- Coal Mill Roller Lift command is generated.After Roller gets lifted
next step is executed
4) Step-4:- Coal Mill Stop command is generated. After time delay of 80
seconds next step is executed.
5) Step-5:- Roller fall command is generated and roller gets fall.
6) Step-6:- Close mill cold air gate & damper.
7) Step-7 :-Opens the fire fighting MOV.
8) Step-8:-Closes the fire fighting MOV after 8 minutes.
9) Step-9:-Close the mill outlet gate. When the mill normally stop, may only
close n-1 outlet gate; When the mill trip, must close completely all outlet
gate.
10) Step-10:-Stop Mill hydraulic oil pump, and close mill seal air valve and
outlet seal valve.
Mill Fast Trip Conditions
 Mill PA flow<38TPH:

If coal Mill in running condition & Inlet PA flow transmitter

value falls below 38 TPH then with time delay of 5 sec Mill fast
stop signal is generated.

 Outlet temperature >105 .C:

If coal Mill outlet pipe temperature two out of three signal

value crosses 105 degree centigrade with time delay of 30 sec
Mill fast stop signal is generated.
 Roller fall & Loading oil pressure <1.5 Mpa:

During mill startup condition on giving roller fall command

from DCS if hydraulic pressure does not increase upto 1.5 Mpa
within time span of 30 sec Mill fast stop is generated.
 Loading oil pump stop:

If loading oil pump is tripped or stopped then with time delay

of 30 seconds Mill fast stop is generated.
 Lube oil system not normal (<0.1 Mpa):

During Coal Mill running condition if lube oil pressure value

drops below 0.1 Mpa with time delay of 3 seconds Mill fast
stop is generated.
Mill Urgent Trip Conditions
 Mill PA flow<35TPH:

If coal Mill in running condition & Inlet PA flow transmitter value falls
below 35 TPH then with time delay of 5 sec Mill urgent stop signal is
generated.

 Seal air and PA DP low (<0.1 Kpa):

Coal Mill in running condition and seal air to primary air differential
pressure falls below 0.1 Kpa then with time delay of 5 sec Mill urgent
stop signal is generated.

 MFT:

Master fuel trip condition generated will cause all running coal mill to
urgent trip without any time delay.

 Any two MDV closed:

Coal Mill running condition and if any two mill outlet damper are
closed then Mill urgent stop signal is generated
 Coal level no flame (2out of 4):
Coal Mill in running condition and if two out of four coal flame
scanner does not sense flame then with time delay of 5 sec Mill
urgent stop signal is generated

 All PA fan stopped:

If all running PA fan are stopped then with time delay of 5 seconds
Mill urgent stop signal is generated.

 Outlet temperature >105’C:

If coal Mill outlet pipe temperature two out of three signal value
crosses 105 degree centigrade Mill urgent stop signal is generated.

 Bearing temp >95’C:

Coal Mill motor drive bearing, non drive bearing & thrust bearing
temperature value crosses more than 95 ‘C Mill urgent stop signal is
generated.

 Feeder running & Mill Trip:

Coal feeder running and coal mill not running Mill urgent stop signal
is generated.
Coal Feeder Start Permission
 Mill running

 Coal level spark permit

 No belt tracking alarm

 Feeder not over temp.<80.C

 Clean out conveyer normal

 Feeder set minimum flow(12 TPH)

 Feeder O/L gate open

 Feeder belt motor normal

 Feeder I/L gate no failure

Coal Feeder Trip Condition
 MFT:
Master fuel trip condition generated will cause coal feeder to urgent
trip without any time delay.

 Coal Mill Urgent stop:

Coal Mill urgent trip condition will cause coal feeder to urgent trip
without any time delay.

 No material (coal) on belt:

Coal feeder in running condition for 20 seconds and material on belt
switch does not sense any coal on belt then with time delay of 120
seconds coal feeder urgent trip is generated.

 Feeder O/L plugged:

Coal feeder in running condition for 20 seconds and if coal feeder
outlet gate flapper switch senses plugged then with time delay of 5
sec coal feeder urgent trip is generated.
 Belt tracking alarm:

If coal feeder belt is swayed on either side of feeder will act belt
tracking switch then with time delay of two seconds coal feeder
urgent trip is generated.

 Feeder over temp>80.C:

Coal feeder temperature value increased more than 80’C then coal
feeder urgent trip is generated.

 Feeder O/L damper closed:

Coal feeder running and outlet damper is closed then with time delay
of 2 seconds coal feeder urgent trip is generated.

 Feeder belt motor failure:

Coal feeder belt motor fail to start then coal feeder urgent trip is
generated