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General
BMS architecture
What is NFPA?
NFPA is an abbreviation for National Fire Protection Association
Established in 1896, NFPA an international nonprofit membership organisation serves as the world's leading advocate of fire prevention and is an authoritative source on public safety
It is the authority on fire, electrical, and building safety.
Its mission is to reduce the worldwide burden of fire and other hazards on the quality of life by providing and advocating consensus codes and standards, research, training, and education.
NFPA's 300 codes and standards influence
NFPA 8501, Single-Burner Boiler Operation; NFPA 8502, Prevention of Furnace Explosions/ Implosions in MultipleBurner Boilers; NFPA 8503, Pulverized Fuel Systems, NFPA 8504, Atmospheric Fluidized-Bed Boiler Operation; NFPA 8505, Stoker Operation; and NFPA 8506, Heat-- Recovery Steam Generator Systems.
An excerpt from the above standard the basic cause of a furnace explosion is the ignition of an accumulated combustible mixture within the confined space of the furnace or the associated boiler passes, ducts, and fans that convey the gases of combustion to the stack.
Interruption of Fuel or air supply or ignition energy to the burners. Fuel Leakage into an idle furnace and the ignition of the accumulation Repeated Unsuccessful attempts to light up without appropriate purging The Accumulation of an explosive mixture of fuel and air as a result of a complete furnace flameout
Requirement
Multiple burner boilers require two independent control systems.
One to control steam production i.e. Boiler Control System and One to control the fuel burning equipment i.e. Burner Management System
NFPA definition
NFPA defines
a Boiler Control System as The group of control systems that regulates the boiler process, including the combustion control system but not the burner management system. and A Combustion Control System is The control system that regulates the furnace fuel and air inputs to maintain the air-fuel ratio within the limits that are required for continuous combustion and stable flame throughout the operating range of the boiler in accordance with demand .
NFPA definition
NFPA defines
a Burner Management System as The control system that is dedicated to combustion safety and operator assistance in the starting and stopping of fuel preparation and burning equipment and for preventing mal-operation of and damage to fuel preparation and burning equipment.
must be designed to ensure a safe, orderly operating sequence in the startup and shutdown of fuel firing equipment and to reduce possible errors by following the operating procedure. is intended to protect against malfunction of fuel firing equipment and associated systems. In some phases of operation, the BMS shall provide permissive interlocks only to ensure safe startup of equipment. Once the equipment is in service, the operator must follow acceptable safe operating practices.
all parts of the BMS shall remain in good working order and in service whenever the burner is in service if the system is to provide the protection for which it is designed.
Prevent firing unless a satisfactory furnace purge has first been completed. Prohibit start-up of the equipment unless certain permissive interlocks have first been completed. Monitor and control the correct component sequencing during start-up and shutdown of the equipment. Provide component condition feedback to the operator and, if so equipped, to the plant control systems and/or data loggers. Provide automatic supervision when the equipment is in service and provide means to make a Master Fuel Trip (MFT) should certain unacceptable firing conditions occur. Execute a MFT upon certain adverse unit operating conditions.
Boiler purge control Fuel safety control Pre-light up control Individual burner control
Ensuring that a predetermined set of fuel and air related permissive conditions are satisfied which shall include
All fuel valves (Shut-off valves, oil valves) closed Either of one FD Fan & ID Fan running All Mills and Feeders stopped and Mill discharge valves closed All PA Fans stopped and PA to Mill inlet dampers closed All scanners sense no flame Air flow is not less than 25% - 35 % (multiple burner boilers) of full load air flow 4 out of 6 secondary air dampers at Purge position No MFT conditions present MFT relay tripped
All FD Fans off All ID Fans off Boiler air flow low for 3 secs Loss of all fuel Loss of all flame Furnace pressure very high/Low Drum level very high/low Critical Flameout Delayed light-up Re-heater protection operated
None of the above trip conditions exist Boiler purge is complete Reset MFT is initiated
NEXT
Implication: Will result in in-sufficient air for the combustion process and the fuel cannot burn
Action: MFT MFT conditions
MFT conditions
MFT conditions
Implication: Will result in explosion or implosion of the furnace resulting in mechanical deformity
Action: MFT
MFT conditions
Critical Flameout
Source : Furnace flame scanners detect 2 out of 3 zones no flame
Implication: Is a consequence of improper combustion in pre-identified zones within the furnace resulting in flame instability which may give rise to improper heat distribution Action: MFT MFT conditions
Delayed light up
Source : MFT reset , LDO shut off valves open and no oil gun in operation (or in other words put into service) within 10 mins of opening of LDO shut-off valves. Implication: Repeated unsuccessful attempts to light up the boiler with oil gun has resulted in accumulation of un-burnt fuel (oil) in the furnace and hence the furnace requires purging.
Re-heater protection
Source : All governor valves closed, HP bypass valve < 2% open with a. at least one feeder running from remote or b. More than 8 out of 12 oil guns in operation Implication: Damage to tubes that can result from firing in excess of safe limit which will cause overheating of re-heater tubes due to absence of a steam flow through it. Action: MFT
MFT conditions
MFT conditions
EFFECTS OF MFT
MFT RELAY OPERATED LDOT HFOT TRIP SEAL AIR FANS TRIP ALL MILLS TRIP ALL FEEDERS
LDO trip valves close command LDO trip valves not closed and LDOT condition is present LDOT relay fail to trip and LDOT condition is present LDO pressure very low for 3 secs and any LDO burner valves not closed Atomising air pressure very low for 3 secs and any LDO burner valves not closed LDO trip valve not open within 10 secs of LDOT reset Any burner valve fail to close despite boiler load being > 50% LDOT hard relay tripped
LDOT can be reset when None of the above trip conditions exist MFT relay is reset Trip valve open is initiated All LDO burner valves are closed
LDO trip valves open LDOT reset LDO pressure healthy Atomizing air pressure healthy
Oil burner start permissives Oil burner light-up Oil burner shutdown Oil burner scavenging
Permission to light LDO is present Burner LDO valve is closed No flame is detected at burner Burner shutdown condition is not initiated Burner spark ignitor power healthy
Atomising air valve open LDO valve open Oil gun inserted Oil flame detected
Burner is in lighting mode Burner is not in operation Feeder is not running from remote Secondary air dampers are initiated to move to oil position ( air flow 30 to 120 T/hr)
Step 2:
Burner is in lighting mode Secondary air dampers are in oil position or Feeder is running from remote Oil gun insertion initiated
Step 3:
Burner is in lighting mode Oil gun inserted Atomising air valve open initiated
Burner is in lighting mode Oil gun inserted Atomising air valve open Scavenge valve closed Spark ignitor inserted Energise spark ignitor
Burner in lighting mode for 60 secs and oil gun not inserted Burner in lighting mode for 60 secs and LDO valve closed Burner in lighting mode for 60 secs and atomising air valve not full open LDO valve not closed and oil gun not inserted LDO valve neither full close for 15 secs nor full open LDO valve not closed for 10 secs and oil flame not detected LDO valve not closed and scavenge valve not closed LDOT MFT Air flow < 10 %
Sequence of operation
Step 1:
Burner oil scavenge required persists Oil gun scavenge not blocked Indicates burner oil gun in scavenge mode
Step 2:
Oil gun in scavenge mode Oil gun inserted Atomising pressure healthy Spark ignitor insertion initiated and 2 min timer triggered to start countdown of scavenge process
Step 3a:
MFT LDOT Either scavenge valve or atomising valve not full open when burner is in scavenge mode, oil gun is inserted, atomizing air pressure is healthy, ignitor is inserted and sparking Either ignitor power is not available or ignitor not inserted when burner is in scavenge mode, oil gun is inserted, atomizing air pressure is healthy, Oil gun scavenge required persists and Atomizing air pressure not healthy Oil gun scavenge required persists and Oil gun not inserted Oil Burner stop command
Step 4: Scavenge valve open Step 3b condition satisfied Atomising air selected
Atomizing
Step 6: Step 5 all conditions remaining except that 2 mins has elapsed since starting of scavenge process
Oil
Initiates
scavenge valve to close, atomising air valve to close, de-energise spark ignitor, retract spark ignitor and simultaneously scavenge required message will disappear
Mill start permissive and Mill starting Operation of Mill discharge valves Feeder starting Feeder normal shutdown Mill normal shutdown Preferential Mill tripping
LOS or emergency stop pressed Mill and feeder running from remote, oil flame not detected with either feeder speed <30 % or coal flame not detected signifying low coal and no ignition source Feeder running from remote and coal and oil flame neither detected assuming flame monitoring system is healthy signifying loss of coal flame without ignition source Loading gas pressure very low Lub oil pressure very low signifying no lubrication to Mill gear box and bearings Both PA fans stopped Mill running from remote for >30 secs and PA flow below minimum Mill running from remote for >30 secs and Secondary air flow < 45% Seal air pressure very low MFT or Mill hard relay
Oil flame is detected Mill discharge valves are closed PA to Mill inlet damper is closed
Note:
Mill running from remote for 10 secs moves the secondary air dampers to PF position
No mill trip condition present and Trip relay reset Either both PA fans running OR one PA fan running with less than 3 mills running Selector switch in remote and breaker in service Seal air pressure healthy Mill outlet temperature > 60C but < 110C Oil flame detected Mill discharge valve open Mill lub oil pressure healthy Mill loading gas pressure healthy PA to mill inlet damper closed
The above conditions gives the permissive to start a Mill and when Mill start is initiated from remote.. MILL STARTS provided Mill is not in shutdown mode
Mill Trip relay reset Oil flame detected MDV not open Seal air pressure healthy
The above conditions gives the permissive to open Mill discharge valve and when Open is initiated .. MDV opens The following conditions need to be true prior to closing a Mill Discharge Valve
The above conditions gives the permissive to close Mill discharge valve and when Close is initiated or MFT or Mill hard relay trip occurs.. MDV closes
Feeder Starting
The following conditions generates a start permissive for a Feeder
Mill Trip relay reset Oil flame detected Feeder selected to remote Seal air pressure healthy Mill running from remote Feeder selected in remote Mill secondary air dampers in PF position ( air flow 80 to 140 t/hr) Mill PA flow not below minimum (not less than 45 T/hr) Feeder trip condition not present and not running from remote
The above conditions gives the permissive to start a Feeder from remote
and when start is initiated .. Feeder starts provided Feeder is not in shutdown mode
Coal flame has been detected Coal flame is healthy Feeder is running from remote for more than 10 mins
The oil burners are now taken out of service For providing support ignition the following conditions need to be true
Coal flame has been detected Coal flame is not healthy Feeder is running from remote
This generates an alarm Mill support ignition required and accordingly oil burners are to be put in service
Oil flame detected LDO valve open for both oil burners Feeder running and speed at minimum
Either of the following conditions generates a trip condition for a Feeder and indicates Feeder in shutdown mode
Permission to stop Feeder persists, Feeder selected to remote, Stop feeder initiated MFT Mill Trip relay Feeder motor protection operated
Mill running from remote Mill differential pressure low Mill running from remote Oil flame detected LDO valve open Feeder stopped
OR
The above condition need to persist for more than 5 mins to initiate a permission to stop a Mill . It signifies Mill is empty. Either of the following conditions below de-energize Mill hard relay and indicates Mill in shutdown mode
Mill is empty, Mill selected to remote, Stop Mill initiated. Inhibits oil burner shutdown until Mill outlet temperature is < 60C and mill is stopped MFT Mill Trip relay
Mill Trip relay reset PA to Mill inlet damper not closed Open Seal air valve initiated
Provided no Seal air valve close signal persists Either of the following conditions will result in closing a Mill Seal Air Valve
Mill trip relay tripped Mill stopped and close seal air valve command initiated
When :
if Mill D is not in service then Mill A trips If Mill A is not in service then Mill D trips If both Mill A and Mill D are in service, Mill A trips if Mill D is the single Mill in the rear OR Mill D trips if Mill A is the single Mill in the front If Mill A and Mill D both are not in service then Mill B trips Mill A and Mill D trips if they are both in service Mill A and Mill B trips if Mill D is not in service Mill B and Mill D trips if Mill A is not in service
Hardware - PLC
EFFECTIVE AND RELIABLE SYSTEM
FOR OVERALL SUPERVISION OF BOILER SAFETY IN A POWER PLANT.
TAKING PREVENTIVE MEASURES IN EXTREME CASES TO TAKE THE WHOLE SYSTEM TO STEP-BY-STEP SHUTDOWN.
Hardware - PLC
THE BMS IS A PLC, PROGRAMMED ACCORDING TO USER NEED. LIKE CONVENTIONAL PLC SYSTEMS THE BMS ALSO CONSISTS
OF THE FOLLOWING PARTS:1. MOUNTING RACK 2. POWER SUPPLY
FOR HOUSING THE WHOLE PLC SYSTEM. FOR SUPPLYING POWER TO THE PLC SYSTEM. THE BRAIN OF THE SYSTEM INTERFACING UNITS BETWEEN SYSTEM & FIELD COMMUNICATION WITH OTHER SYSTEMS, ETC. HIGH SPEED COUNTER, THERMOCOUPLE SENSORS (NOT IN BBGS)
The Tricon controller uses three identical channels to process single data from field Each channel independently and parallely executes the application program which can remain in the form of Ladder Logic, Functional Block Diagram or Statement List in the processors Specialised hardware / software voting mechanisms qualify and verify digital inputs / outputs from / to field Analog inputs are subjected to a MEDIAN VALUE selection Each channel is isolated from the others and no single point failure in any channel can pass to another channel
TMR Architecture
Input Leg A Main Processor A Output Output Leg Leg A A Output Output Leg Leg B B
A B +V C
Input Leg B
Main Processor B
Input Leg C
Main Processor C
Loopback Loopback
Fault Tolerant The Ability of the System to Continue to Perform its Function in the Presence of Faults and Errors. No Single Point of Failure will Shutdown the System Fail-Safe If the System does Fail it will Fail to the Safe State or the state of the Equipment Under Control (EUC) when safety is achieved - de-energized for ESD Systems PFD - Probability-to-Fail On Demand Availability The probability that the system will be operational at some instant of time
Diagnostic Features