BHEL - TRICHY

TRAINING PROGRAMME FOR POWER SECTOR EXECUTIVES ON CFBC BOILERS CONTROLS & INSTRUMENTATION
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SCOPE OF SUPPLY
ELECTRICALS, CONTROLS & INSTRUMENTATION
A. ELECTRICALS:

1.HT / LT Motors, Electrical actuators and Pneumatic actuators. 2.Local push button stations for soot blowers. 3.Boiler sootblower LTMCC.

SCOPE OF SUPPLY
B. INSTRUMENTATION & CONTROLS: 1. Local gauges for pressure and temperature measurements. 2. SH, RH and drum metal temperature measuring thermocouples. 3. Bearing temperature measurement of PA, ID, SA fans and their drives, vibration monitoring system for PA, SA & ID fan bearings (single axis), HT motor winding temperature measurement, SA & PA flow element pressure and differential pressure switches for startup burners & lances etc.
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SCOPE OF SUPPLY
4. Impulse lines along with fittings (same as that of parent material )for instruments in pressure parts and non pressure parts. 5. Instrument air supply lines 6. Lignite feeder control panel ( VFD based). 7. Instrument cables (Screened ) upto local junction box (for process switches). 8. Local junction boxes (for terminating SH/RH & drum Metal Temperature Measurement thermocouples).
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SCOPE OF SUPPLY
9. Cable trays (perforated) for Instrument cables upto JB. 10.One no. Electronic water level indicator (single vessel) - BHELVISION 20. 11. Local Controller for SH & RH ERVs 12.BMS Panel (Supply by BHEL EDN Bangalore). 13. Soot blower Panel for auto sequential operation of soot blowers (Supply by BHEL EDN Bangalore).
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SCOPE OF SUPPLY
14. Soot blower Panel for auto sequential operation of soot blowers (Supply by BHEL EDN Bangalore). 15. Fuel oil flow meter (Positive displacement type). 16. Spray flow measurement (orifice) for SH & RH.

EXCLUSIONS
1. Lighting at site and boiler area. 2. Complete electrical power distribution system like transformers, HT switchboards, boiler HTMCC, boiler LTMCC ,Boiler emergency LTMCC etc. 3. Earthmat, earth risers, earth pits, below ground and above ground earthing. 4. All HT, LT power and control cables including those interconnecting soot blower control panel to SB MCC & SB MCC to local push button station /Soot blowers. This also includes cable trays and accessories. 7

EXCLUSIONS
5. Lightning arrestor and Aviation lamps for chimney. 6. All remote instruments. 7. Distributed control system (DCS). 8. Power distribution boards. 9. Electrical power supplies (both AC and DC). 10.Uninterrupted / Emergency power supply units (Both 3 Ph, 415 V, AC and 1Ph, 230 V, AC supply). 11. Emergency instrument air supply system.
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EXCLUSIONS
12. Air compressor and its accessories.

13. Intercommunication and telephone systems. 14. Instrumentation cables and cable trays between Field Junction Box and DCS marshalling rack. 15. Complete online flue gas emission monitoring system including Oxygen, SO2, NOX, SPM, CO analyzer etc. 16. Complete online steam and water analysis system including pH, conductivity, silica analysers etc. 17. Feed water and Main steam flow elements (PEM Supply). 9

EXCLUSIONS
18. Thermocouples along with thermowell for remote monitoring and controls 19. Process transmitters (Smart type) including hand held configurator. 20. Fire detection and alarm system 21. Ventilation and AC equipment. 22. All other equipments other than those specifically included under scope of supply.

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PID OF AIR & FLUE GAS

O

11

PID OF LIGNITE, LIMESTONE, ASH

EXTERNAL LIGNITE FILLING SYSTEM. EXTERNAL LIGNITE FILLING SYSTEM. EXTERNAL LIMESTONE MILLING SYSTEM FILTER CLEANING SYSTEM
LIME STONE 1 FILTER AIR

LIGNITE BUNKER 1

LIGNITE BUNKER 2

LIME STONE 2 FILTER AIR

FILTER CLEANING SYSTEM

EXTERNAL LIMESTONE MILLING SYSTEM

LIMESTONE SILO 1
PLANT AIR LIMESTONE 1 FLUID AIR LINE 1

LIMESTONE SILO 2
PLANT AIR

LIGNITE CONVEYOR 1
LIGNITE FEED CONTROL

LIGNITE CONVEYOR 2
LIGNITE FEED CONTROL

LIMESTONE 2 FLUID AIR LINE 1

PURGE & SEAL AIR LIMESTONE 1 FLUID AIR LINE 2 SV LIGNITE AL FDR1 PURGE VLV LIMESTONE 1 AL FDR 1 LIMESTONE SPEED CONTROL LIMESTONE 1 AL FDR 2 LIGNITE AL FDR1 PURGE & SEAL AIR

LIMESTONE 2 FLUID AIR LINE 2

CYCLONE 1

CYCLONE 2
LIGNITE AL FDR2

SV LIGNITE AL FDR1 PURGE VLV LIMESTONE 2 AL FDR 1 LIMESTONE SPEED CONTROL LIMESTONE 2 AL FDR 2

PLANT AIR

COMBUSTOR
LIGNITE GATE VLV 1 LIGNITE GATE VLV 2

PLANT AIR

LIMESTONE 1 GATE VALVE LIMESTONE 1 SEAL AIR VALVE

LIMESTONE 2 GATE VALVE

LIMESTONE 2 SEAL AIR VALVE

SEAL POT 1

SEAL POT 2

BED ASH SYSTEM BED ASH TO COMBUSTOR BOTTOM ASH TRANSPORT (REF DRG.NO:0-97-400-80016) FILTER CLEANING SYSTEM BED MTL FLTR AIR FAN

SH2A

RH1

SH2B

EVAP

PURGE & SEAL AIR SYSTEM ( LIGNITE BUNKER 2)

PURGE & SEAL AIR SYSTEM ( LIGNITE BUNKER 1)

BED MATERIAL SILO

SV BED MTL FLUID AIR VLV BED MATL AL FEEDER SV BED MATL FEED GV

COOLING WATER

PURGE & SEAL AIR SYSTEM

COOLING WATER

AC1 BED ASH AL FEEDER

AC2 BED ASH AL FEEDER

SV BED MATL SEAL AIR ISO VLV

ASH HANDLING SYSTEM

ASH HANDLING SYSTEM

SV SEAL AIR BLOWER 1 DAMPER

SV SEAL AIR BLOWER 2 DAMPER

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PRESSURE MEASUREMENT IN CFBC COMBUSTOR

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TEMPERATURE MEASUREMENT IN CFBC COMBUSTOR

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START UP SEQUENCE
MANUAL START OF ID FAN FUNCTION GROUP 1 OR 2 MANUAL START OF FN. GROUP FOR OTHER ID FAN FN GROUP ID FAN IN OPERN. YES PUT ALL FN GROUP TO AUTO MODE -FG FANS & BLOWERS -FG BOILER PURGE -FG FANS -FG PA FAN 1 -FG PA FAN 2 -FG SA FAN 1 -FG SA FAN 2 -FG FBHE BLOWERS -FG ID FAN 1 -FG ID FAN 2 NO

SELECTIONOF PA FAN & SA FAN TO BE STARTED FIRST

MANUAL START OF FN GROUP FANS & BLOWERS -SEAL POT BLOWERS ON -ASH COOLER BLOWERS ON -FN GROUP OF SELECTED SA FAN AUTO ON -FBHE EMPTY CHAMBER BLOWER ON -FG OF SELECTED PA FAN AUTO ON -ALL AIR CONTROLLERS AUTO

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START UP SEQUENCE CONTD

A T COMB. > PERMISSIVE TEMP. OIL (590) MANUAL START OF FG BOILER PURGE -FG PA FAN AUTO ON -PURGE SET POINTS FOR ALL AIR FLOW CONTROLLERS -FG FBHE BLOWERS AUTO ON PURGE TIM ERS RUNNING -FG FBHE BLOWERS AUTO OFF -FG FANS AUTO OFF -NORMAL OPERN. SET POINTS FOR ALL AIR FLOW CONTROLLERS.

MANUAL START OF FG BED LANCE T COMB. >PERMISSSIVE TEMP. LIGNITE (650)

MANUAL START OF FG LIGNITE FEEDING 1 OR 2

MANUAL START OF FG START UP BURNER 1 OR 2

MANUAL START OF FG FBHE BLOWERS

WARM UP BED MATERIAL

LOAD RISE WITH MORE LANCES OR SECOND LIGNITE FEEDING

MANUAL START SECOND SUB T COMB. >PERMISSIVE TEMP. OIL

LOAD >50% REDUCE LOAD OF SUB MANUAL START OF FG FANS -START OF 2ND FG SA FAN -START OF 2ND FG PA FAN -START OF 2ND FG ID FAN

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START UP / SHUT DOWN / TRIP (SCHEMATIC)

S TA R T T> 575
N Y C O LD S TA R TU P

U N IT P U R G E T R IP
Y

S /U B U R N E R S

T< 600

T> 600
Y

T< 750
Y Y

T< 550

W A R M R E S TA R T

T R IP
Y

B E D L A N C E S

T< 750

T> 750

T< 750

T> 750
Y Y

T< 700

T R IP

S O L ID F U E L

B E D L A N C E S C O F IR IN G O P T IO N A L
Y Y

T~ 850
Y

T> 600

T< 725

S H U T D O W N
Y

N O R M A L O P E R A T IO N
H O T R E S TA R T

T< 960
N

B P # 1 T R IP

T> 960

N B L R # 3 T R IP B L R # 1 T R IP B L R # 2 T R IP

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BOILER PROTECTION 1(1)

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BOILER PROTECTION 1(2)

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BOILER PROTECTION 1 (SUB)

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BOILER PROTECTION 1
AT THIS TOP MOST LEVEL OF TRIP CONDITION, ALL DRIVES, FANS, BLOWERS, START UP BURNERS, LANCES AND LIGNITE FEEDER ETC., EXCEPT ID FANS WILL TRIP. OVER PRESSURE PROTECTION BOILER IS PROTECTED FROM DAMAGE DUE TO OVER PRESSURE WHEN CONVECTIVE PASS INLET PRESSURE IS >40 mBAR. THE SELF REGULATED OVER PRESSURE RELIEF DAMPER LOCATED AT THE ESP INLET WILL OPEN AUTOMATICALLY. PRIOR TO THIS WHEN PRESSURE IS >30 mBAR, ALL THE FANS AND BLOWERS (EXCEPT ID FAN) AND FIRING SYSTEM WILL TRIP. ID FAN CONTROL WILL FULL OPEN THE IGV.
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BOILER PROTECTION 1
BOILER TRIP CONDITION BOILER PROTECTION-1 WILL ACTUATE AT ANY ONE OF THE FOLLOWING CONDITIONS OCCUR. 1.EMERGENCY PUSH BUTTON PRESS 2.FEEDWATER TANK LEVEL VERY LOW 3.DRUM LEVEL VERY LOW (-305MM) 4.BOTH ID FANS (I&II) SPEED VERY LOW(<) 5.BOTH ID FANS (I&II) OUTLET DAMPERS CLOSE 6.INSTRUMENT AIR PRESSURE VERY LOW <4.5 KG/CM2 7.MAIN STEAM PRESSURE STOP VALVE NOT OPEN WHEN MS PRESSURE >20 BAR 8.PRESSURE INLET CONVECTIVE PASS >30MBAR
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BOILER PROTECTION 1
9. PRESSURE INLET TO ID FAN I&II <-40 MBAR 10. HPBYPASS NOT OPEN WITHIN 2 SECONDS WHEN TURBINE TRIP. 11. COMBUSTOR MIDDDLE TEMPERATURE >9500C 12. COMBUSTOR LOWER TEMPERATURE >9500C 13. TEMPERATURE OUTLET CYCLONE 1 >9500C 14. TEMPERATURE OUTLET CYCLONE 2 >9500C 15. TOTAL COOLING WATER FLOW VERY LOW 16. MAIN STEAM TEMPERATURE VERY HIGH >5600C 17. RH STEAM TEMPERATURE VERY HIGH >5600C

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BOILER PROTECTION 2

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BOILER PROTECTION 2

THIS PROTECTION WILL ACT WHEN COMBUSTOR MIDDLE OR LOWER TEMPERATURE IS <5500 C OR PRIMARY AIR FLOW <16 KG/CM2 OR EMERGENCY STOP FOR LANCES WHEN THIS CONDITION OCCURS, ALL THE BED LANCES WILL BE PUT OFF.

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BOILER PROTECTION 3

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BOILER PROTECTION 3

THIS WILL ACT WHEN COMBUSTOR MIDDLE OR LOWER TEMPERATURE IS <6500 C. WHEN THIS TRIP CONDITION OCCURS ALL THE DRIVES RELATED TO LIGNITE FEEDER AND LIMESTONE FEEDING SYSTEM WILL TRIP. IE CONVEYOR , AIR LOCK FEEDER & GATE VALVES.

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BOILER PROTECTION SG COOL DOWN

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BOILER PROTECTION SG COOL DOWN

THIS IS TO PROVIDE SUFFICIENT COOLING OF BOILER COILS PARTICULARLY IN FBHES AND FIRST PASS AND SECOND PASS ETC., AT BOILER TRIP CONDITIONS. SG COOLING DOWN PROTECTION WILL ACTUATE WHEN BOILER PROTECTION 1ACTUATES AND WHEN COMBUSTOR LOWER TEMPERATURE IS >4500C AND ALSO DURING STATION BLACK OUT. AT SG COOLDOWN ANY ONE OR MORE OF THE FOLLOWING SYSTEM WILL TRIGGER DEPENDS ON THE NATURE OF THE TRIP AS DETAILED IN THE LOGIC DIAGRAM. A)DIESEL ENGINE DRIVEN EMERGENCY FEED PUMP ON. B)TRIGGERING HP STEAM BYPASS C)TRIGGERING LP STEAM BYPASS D)TRIGGERING EMERGENCY COOLING WATER PUMPS ETC
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BOILER PROTECTION REHEATER

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BOILER PROTECTION REHEATER

THIS IS TO PROTECT THE RH BUNDLES IN FBHE 1. WHEN RH OUTLET STEAM TEMPERATURE IS VERY HIGH (>5600C) IT WILL ACTUATE THE RH PROTECTION WHICH WILLTRIP THE FBHE 1 BUNDLE CHAMBER BLOWER AND CLOSES THE RESPECTIVE SPIESS VALVE IN SEAL POT 1. THIS WILL REDUCE THE PICK UP IN RH1.

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LIST OF CLOSE LOOP CONTROLS

SL.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION OF CONTROL SCHEME II PASS PRESSURE CONTROL DRUM LEVEL CONTROL SH2 OUTLET STEAM TEMPERATURE CONTROL MAIN STEAM TEMPERATURE CONTROL RH1 OUTLET STEAM TEMPERATURE CONTROL MAIN RH STEAM TEMPERATURE CONTROL START UP BURNER CONTROL BED LANCES CONTROL PA FLOW CONTROL SA PRESSURE CONTROL SA FLOW CONTROL COMBUSTOR DIFFERENTIAL PRESS. CONTROL COMBUSTOR MIDDLE TEMPERATURE CONTROL

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LIST OF CLOSE LOOP CONTROLS

SL.NO 14 15 16 17 18 19 20 21 22 23 24 25 26 DESCRIPTION OF CONTROL SCHEME SO2 CORRECTION CONTROL O2 CORRECTION CONTROL COMBUSTION CONTROL BLOWDOWN TANK LEVEL CONTROL LOAD MASTER CONTROL COMBUSTOR SPIESS VALVE CONTROL EVAPORATOR SPIESS VALVE CONTROL ATOMISING STEAM PRESSURE CONTROL FO Vs ATOMISING STEAM DP CONTROL FO PUMP OUTLET PRESSURE CONTROL LDO Vs ATOMISING DP CONTROL FO TEMPERATURE CONTROL SB STEAM PRESSURE CONTROL.

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LIST OF OPEN LOOP CONTROLS

SL.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION OF CONTROL SCHEME ID FAN 1& 2 PURGE AND SEAL AIR BLOWER 1/2 SEAL POT BLOWER 1& 2 EMPTY CHAMBER BLOWERS 1 & 2 ASH COOLER BLOWER 1 & 2 SA FANS 1 & 2 PA FANS 1 & 2 BED MATERIAL FEEDING FBHE BLOWER 1 & 3 FBHE BLOWER 2 & 4 BOILER PURGE START UP BURNER 1 START UP BURNER 2

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LIST OF OPEN LOOP CONTROLS

SL.NO 14 15 16 17 18 19 20 21 22 23 24 25 DESCRIPTION OF CONTROL SCHEME BED LANCES LIGNITE FEEDING 1 LIGNITE FEEDING 2 LIMESTONE FEEDING 1 LIMESTONE FEEDING 2 SOOTBLOWERS CONV. PASS SOOTBLOWERS AH PASS EMERGENCY COOLDOWN BOILER PROTECTION I BOILER PROTECTION II BOILER PROTECTION III REHEATER PROTECTION

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Ash discharge valves location & control

36

Ash discharge valves location & control

ASH DISCHARGE VALVES ARE LOCATED AT 7 PLACES TO FACILITATE THE DISCHARGE OF ASH INVENTORY. THE DISCHARGE WILL BE USEFUL FOR CONTROLLING THE COMBUSTOR TEMPERATURE, RH1 STEAM TEMPERATURE, COMBUSTOR DP & LOAD CONTROLS.
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Soot Blower location

SOOT BLOWING SYSTEM
FLUE GAS FROM CYCLONE

AH TOP BLOCK 17 18 19 20

} }
} }

S.A 1

SH II 2 RH II 4

P.A

21

22

23

24 SH II 6 ASH RH II 8

FBHE
400

25

26

27

28

AH MIDDLE BLOCK

} } } }

LEGEND: ECO 10 ECO 12 1. LONG RETRACTABLE SOOT BLOWER AT LEFT SIDE 2. LONG RETRACTABLE SOOT BLOWER AT RIGHT SIDE 3. HALF RETRACTABLE SOOT BLOWER AT LEFT SIDE 4. HALF RETRACTABLE SOOT BLOWER AT RIGHT SIDE

29

30

32

P.A

AH BOTTOM BLOCK

ECO 14 ECO 16 NOTES: 1.LAMP NO GLOW - BLOWER NOT IN OPERATION / BYPASSED 2. RED FLASHING - FORWARDING 3.RED SLOW FLASHING - RETRACTING 4. RED STEADY GLOW - BLOWING COMPLETED

TO ESP

ASH

ASH

600

ALL LINES - GRAY BACKGROUND - WHITE SB - RED

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Soot Blower location

SOOT BLOWERS ARE SUITABLY LOCATED TO CLEAN THE HEATING SURFACES OF SIPERHEATERS, REHEATERS AND ECONOMISERS IN THE CONVECTIVE PASS & AIR HEATER SURFACES IN THE AH PASS. CLEANING OF THE HEATING SURFACES WILL ENABLE BETTER HEAT TRANSFER & ALSO REDUCE THE PRESSURE LOSS IN THE SUPERHEATERS, REHEATERS, ECONOMISERS & AIR HEATERS.
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UPS / EPS REQUIREMENT

COM BUSTOR SPIESS VALVE 1 COM BUSTOR SPIESS VALVE 2 SP1 SPIESS VALVE 1 SP1 SPIESS VALVE 2 SP2 SPIESS VALVE 1 SP2 SPIESS VALVE 2 FBHE 2 SPIESS VALVE ECO.FEED PIPE M AIN ISO (FW004) ECO.FEED PIPE M AIN ISO BYPASS(FW004A) DRUM EM ERGENCY DRAIN (BW054) DRUM CBD LINE BLOW DOWN VALVE (BW060) DESH1 SPRAY M AIN LINE ISO (SW013) DESH1 SPRAY BYPASS LINE ISO (SW019) DESH2 SPRAY M AIN LINE ISO (SW043) DESH2 SPRAY BYPASS LINE ISO (SW049) RH DESH SPRAY CTRL STN.M AIN LINE ISO(SW073) RH DESH SPRAY CTRL STN.BYPASS LINE ISO(SW079) M S LINE START UP VENT ISO (M S101) M S LINE SUV REG VALVE (M S102) M S LINE START UP VENT ISO (M S103) HOT REHEAT LINESTART UP VENT REG (M S086) ECO RECIRCULATION (FW 019) ISO VLV B/W EM ERGENCY AND NORM AL CW HDR(RETURN) ISO VLV B/W EM ERGENCY AND NORM AL CW HDR(SUPPLY) EM G.CW PUM P TO HDR LINE (SUPPLY) EM G.CW RETURN LINE TO TRENCH EM G. COOLING WATER PUM PS BOILER FEED PUM P A&B - ISOLN. VALVE BOILER FEED PUM P A&B - ISOLN.BYPASS VALVE M S STOP VALVE M S STOP VALVE BYPASS HYDRAULIC PUM P FOR HPBYPASS 40

DRUM EM ERGENCY DRAIN TO IBD (BW055) M S LINE SUV REG VALVE (M S104) DRUM CBD LINE M AIN ISO (BW059) HOT REHEAT LINESTART UP VENT ISO (M S085)

DC REQUIREMENT
EMG.BOILER FEED PUMP - DISCHARGE ISO VLV EMG. FW ISO VLV - SPRAY TO HP BYPASS DURING STATION BLACK OUT EMG. FW ISO VLV - SPRAY FOR MSL STEAM TO DEAERATOR DURING BLACK OUT LIGNITE GATE VALVE 1 LIGNITE GATE VALVE 2
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