7/3/2019 FSSS | THERMAL POWER PLANT A-Z

8th March 2015 FSSS

2. FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS )

FURNACE SAFEGUARD SUPERVISORY SYSTEM is used with all CE steam generators and in short it is called FSSS.
Generally Furnace oil or any kind of fuel is the main initiator of explosion hazards. It has been observed that maximum hazards
occur during start-up; shut down and low load operation. So FSSS has been developed to offer maximum protection of Boiler
and minimize the human error.
The logic is functionally divided into Unit logic, Elevation logic and corner logic. Unit logic supervises the overall furnace. It
monitors all critical parameters of fuel firing system and also supervises furnace purge after tripping of the Boiler.
The Elevation logic is an intermediate logic, which depends on the operator, or the Unit logic for initiation of starts or stops actions.
In addition, it also provides essential trip commands to the corner logic.
The corner logic depends on Elevation logic commands for initiation of an action. During manual operation, the corner logic
computes its own permissive based on ignition energy availability, status of various corner devices and other factors for
sequencing of individual fuel, air or steam valve operations. However, emergency trip signals, originating in unit logic are
transmitted via Elevation logic and cause immediate closure of fuel valves.

FUEL FIRING SYSTEM

Fuel firing system with BHEL Boiler is typically known as Tangential Firing system. Fuel and Air admitting nozzles are placed in
four corners of the furnace so that the air fuel mixture steams tangent to an imaginary circle called as FIRE BALL. Here Burner
tilting mechanism is provided which is utilized to up and down all four corners wind box nozzles simultaneously. By this system, the
steam temperature can be controlled.
The fuel firing equipment consists of four-wind box assemblies located in four corners. Each wind box assembly is divided into
no of compartments. The coal compartments contain coal nozzles in elevations. Oil Guns are provided in alternate elevation to
coal elevations. The topmost, bottommost and the balance intermediate elevations are called Auxiliary elevations.
AB elevation is provided with oil guns of both HFO & LFO and other elevations (CD & EF) are provided with HFO.
Atomisation of HFO is performed with steam and LFO is done with Air.
Coal is fed to the Mill and mixed with hot & cold air. This air dries the coal and picks up milled product and carries through the
coal burner to the furnace.
The secondary air, which is taken from FD fan, passes through the Regenerative Air Heater and to the pair of wind box.
Secondary air that is admitted through fuel nozzle is called fuel air. Auxiliary air passes through the compartments above and
below the fuel nozzle. Dampers are provided in the wind box for control of air to the individual compartments can be
modulated to achieve better combustion in the furnace.

SECONDARY AIR DAMPER CONTROL

There are total 4 Auxiliary Elevations, 3 Fuel oil cum Aux air Elevations and 6 coal Elevations in a 210 MW Boiler. The lower
most Elevation AA serves better for slagging control and is not connected to SADC. This elevation is locked at fixed opening
position.
The purpose of wind box Dampers is distribution of air rather than flow control. It maintains the proportion of secondary air
admitted to an elevation in relation to the sec. Air admitted through adjacent Aux air compartment. This depends on a wind box
to furnace differential pressure setting. The factors, which determine the setting, are:

a) Ignition stability
b) Ignition point relative to fuel nozzles
c) Overall combustion in the furnace
The wind box to furnace D.P. is characterized as a function of Boiler load, which is determined by steam flow index. A
function generator is used to form the curve. Bias can be added to the formed set point.

Till the Boiler load is 30%, all elevations of aux air dampers modulate to maintain a pre determined (approx 1.5” WC) set
point DP between the wind box and furnace.
When unit load exceeds 30%, the DP set point is changed and ramps upto a higher setting (approx 4” WC). Coal elevation
dampers remain closed till the associated feeder is not proven. Once the elevation is established, the respective damper
modulate as a function of coal feed rate. Oil elevation dampers function with Aux air control so long they are not fired.
These dampers go for a preset opening during LO/HO firing.
https://powerplanta2z.blogspot.com/2015/03/fsss.html 1/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

When unit load is reduced below 30%, the aux air dampers open in a timed sequence starting with the lowest elevation of
dampers.

When unit trip, all aux air dampers will maintain the status quo. All aux air dampers will open fully when both FD fans are
off.

FUEL (OIL) DAMPERS

Elevation AB, CD, EF dampers are open to a preset position according to oil firing.

FUEL (COAL) DAMPERS

All FUEL (AIR) DAMPERS are normally closed. They will open 50 secs after the associated feeders are started and modulate
as a function of feeder rate signal. 50 secs after feeders are removed from the service, the dampers will close.
FUEL (AIR ) DAMPERS will open fully for loss of both ID/FD fans or MFT or 24 V DC supply.

OVER FIRE AIR DAMPERS

These dampers are positioned as a function of the Boiler load signal.

FSSS FUNCTIONS
The following operational functions are included in the FSSS
1. Furnace Purge Supervision.
2. Scanner Air fan control.
3. Light oil control and supervision.
4. Heavy oil control and supervision.
5. Seal air fan control.
6. P.A. Fan logic.
7. Pulveriser Feeder control and supervision.
8. Flame Scanner intelligence.
9. Boiler Trip Protection and First out Monitoring.
Furnace purge

Prior to any fuel firing or after a Boiler trip, a furnace purge cycle is mandatory to clear residual combustible mixture or
volatile gases entrapped in the Boiler. 30% Air passes through Boiler for five minutes. A purge is permitted when all scanners
sense no flame, all fuel shut off devices are closed and none of the Boiler trip condition persist. The MASTER FUEL RELAY
(MFR ) gets reset on completion of purge cycle.

All the Auxiliary and Fuel air dampers are opened during the Post Trip Purge cycle. These are set to modulation on completion
of Post Purge.
Tripping of ID and FD fans is initiated if the furnace pressure V. High or V. low actuates after expiry of post trip purge cycle.

Scanner Air Fan Control

Flame scanner head is getting air from scanner air fan. There are two fans in the system, one main and another one stands by.
First one is AC driven and later one is DC driven. The stand by fan cuts in automatically when the scanner duct to furnace DP
goes below 150 mm WC OR when there is loss of unit 24 V DC.
If one scanner fan fails to start within 5 secs after receiving the start command, other scanner fan will start automatically.

When both the FD fans are off OR loss of unit 24 V DC, scanner emergency damper will open. Damper closes automatically
when any FD fan ON.

v FLAME SCANNER

Safe flame scanner system monitors good flame at a zone inside the Boiler and signals the flame status to the Burner
Management System.

Safe flame has two main sections

https://powerplanta2z.blogspot.com/2015/03/fsss.html 2/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

1. Local boiler mounted system items i.e. guide pipe assembly and flame scanner assembly including housing electronics.
2. Remote electronic card.

There are two types of scanner viz safe Flame-1 and safe Flame-ii. SF-1 can detect one fuel flame and SF-ii can detect two
different fuel flames in the same combustion area. So in fossil fired boiler SF-1 is used for fireball flame and SF-ii is used for
detection of both oil gun and background fireball flame. However there is no change in the flame scanner head assembly.

v Selection of Light oil / Heavy oil Firing

Oil elevation AB is provided with Light oil / Heavy oil firing. Light oil or Heavy oil firing can be selected from the console /
CRT provided following conditions is satisfied:
1. All HO & LO nozzle valves are closed in AB elevation.
AND
2. HO / Lo start permissive is available.

v Light oil / Heavy oil Trip Valve Control

Once the Boiler Trip circuit is reset and all the light oil / Heavy oil nozzle valves are proven closed, LOTV / HOTV will open
provided the LO / HO header pr is adequate. LOTV / HOTV will be closed for the following condition:

1. MFR
2. Light oil / Heavy oil header pr very low
3. Atomising air pr / BAS header pr very low & No light oil / heavy oil elevation in start/stop

v Light Oil / Heavy Oil Elevation Start

Light oil can be fired at elevation AB only and in pair mode basis. Heavy oil can be fired at elevation AB, CD and EF in pair
mode basis. Pair mode is diagonally basis i.e. 1&3 or 2&4.
To place the Light oil / Heavy oil guns in service at any elevation proceed as follows:

1. Select Light Oil / Heavy Oil firing.

2. Establish Light Oil / Heavy oil elevation start permit if the following condition is satisfied.

a) No MFT
b) Heavy oil / Light oil Trip v/v fully open.
c) Pulverizer / Feeder start permit available.

Pressing the associated ‘PAIR START’ push button when the above conditions are satisfied, will initiate a 70 sec. Start time.
After coming first Pair say 1&3, a start command (after 15 sec of first pair completion) will generate to start the second Pair
say 2&4.

At the end of 70 sec, Heavy oil pair start trail time of the second pair of oil guns, a minimum of 3 of the 4 HO nozzle v/v at the
must be proven open; if not, an unsuccessful elevation start alarm is initiated. This will stop corners1&3 and 40 sec later 2&4.

v PULVERIZER & AUXILIARIES:

Each unit has been provided with 6 nos of Ball and Race mills. Lubrication system, seal air fan, pulv. Disch. v/v, hot primary
fan, hot air gate, raw coal feeder and R.C. feeder outlet gates are auxiliaries to each pulverizer. Isolation Dampers are provided
in all the above(except Lubrication system) for positive isolation of the Ball and Race mill when it is tripped.

v LUBRICATION SYSTEM

Each pull. Is provided with two Bearing Lub oil p/p serving one as main and the other stand by. Any p/p can be started from the
console. The stand by p/p gets a start command when main p/p has not been proven on within 5 sec OR main p/p running
AND Lub oil flow is low.

https://powerplanta2z.blogspot.com/2015/03/fsss.html 3/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

Lob oil p/p is stopped under any one of the conditions:

1. Respective push button pressed from console.
2. A p/p is ON for more than 5 secs. AND Lub oil flows low for more than 10 secs.
3. Both Lub oil p/p ON AND Lub oil flow is low for more than 5 secs.
4. Pulv. Is off AND Pulv. / Seal Air DP is low for more than 10 secs.

For Pulv. Ready following conditions are to be satisfied:

1. Any Lub oil p/p is ON AND

2. Lub oil flow is more than low condition AND
3. Pulv. Gas pr is not low AND
4. Pulv. Release is available.

v SEAL AIR FAN

Each Pulv. Is provided with Seal air fan, which is taking suction from atmosphere through filter. Seal air fan is provided
with an outlet damper at fan outlet, which is pneumatically operated. In addition one more open-close isolating damper is
provided at the branch off point to mill.
Seal Air fan can be started if outlet damper is closed AND No stop command to seal air fan.

Seal air fan is stopped from stop PB on console or under a MFT condition.

Seal air fan outlet damper is commanded to open from console once the seal air fan is ON. Seal air fan outlet damper is
closed automatically when seal air fan is off for more than 10 secs OR seal air fan is off AND S.A fan outlet damper close
PB is pressed.

Seal air damper to mill is open when Seal air fan is on AND outlet damper is open AND Fire fighting / Inerting command
is not present. Seal air damper to mill is commanded to close when “ Pulv. Trip “ command is present OR Fire fighting /
inerting command is present.

v PRIMARY AIR FAN

P.A fan ready will be available on satisfying of the following conditions:

1. NO MFT
2. Pulverizer ignition permit is available.
3. Hot air gate is closed.
4. Coal elevation start permit is available.
5. P.A fan inlet damper in minimum position.

6. P.A fan Lub oil system is healthy.

7. Seal air-Hot P.A DP is OK.
8. P.A fan motor switchgear in service position.

P.A fan can be started from console after fulfilling the above conditions. Also putting ‘ON’ command to Auto sequence can
start P.A fan
A 2 secs pulse is sent to PA fan motor Breaker for starting.

P.A fan is stopped under ‘any one’ of the following conditions.

1. P.A fan stop PB pressed.
2. Pulv. Off AND stop Pulv Auto sequence.
3. P.A fan motor Electrical trip.
4. MFT
5. P.A fan Lub oil system failed.

https://powerplanta2z.blogspot.com/2015/03/fsss.html 4/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

6. Pulverizer Trip condition is present.

7. 6.6 KV supply not available or failed.
8. Individual Elevation control supply 24 V DC failure will also trip the individual P.A fan.

P.A General shut off damper is a biplane damper and is provided with a ‘vent valve’ to release the entrapped hot air in between
to the atmosphere. This vent v/v is ‘opened’ when P.A General S/O damper is closed and ‘closed’ when P.A General S/O
damper is opened.
P.A General S/O damper will be open when P.A fan start pulse available OR Respective open PB is pressed in console AND
Pulv. Discharge v/v open.
P.A General S/O damper is closed if the following conditions exist for more than 10 secs.
Close PB depressed OR Pulv. Trip OR Fire fighting / inerting command is present AND P.A fan is off.

v PULVERIZER DISCHARGE VALVES

Each pulverizer is provided with two pulverizer discharge valves in the pulv. Outlet. It will open after giving command through
open PB OR Seal air to Hot PA DP is adequate AND Pulv trip OR Fire fighting / inerting command not present.
Pulverizer discharge valves will be closed if Pulv trip OR Fire fighting / inerting command not present OR pulv discharge close
PB pressed AND pulv is off.

v PULVERIZER(BALL & RACE MILL)

Pulverizer will ON when all the following conditions are satisfied:

1. Pulverizer Ready condition present.
2. Pulverizer Release available.
3. Pulverizer ignition permit present.
4. PA fan ON for more than 20 secs.
5. PA General S/O damper is open.
6. Pulverizer motor Breaker in service position.
7. Pulverizer start PB pressed AND Pulverizer PB not depressed.
AND
Pulverizer manual mode
OR
Pulverizer auto start under Auto strat programme.

8. Pulverizer stop / trip not present.

Pulverizer will be tripped under any of the following conditions :
1. MFT.
2. Pulverizer release not available.

3. Pulverizer discharge valve not opened.

4. P.A.Fan is ‘off’ & Pulverizer is ‘on’.
5. No Seal Air to pulverizer for more than 60 secs. & Pulverizer is ‘on’.
6. Pulverizer lub oil press. very low for more than 5 secs.
7. Pulverizer loading gas press. very low for more than 5 secs.
8. P.A.Fan ‘on’ for more than 20 secs. And P.A. press. Low.
9. Pulverizer Motor Electrical trip.
10. Pulverizer motor 6.6 kV supply failure.
11. Pulverizer start available AND Fail to start within 10 secs
12. Loss of any FD fan (When no of working mills more than 3 applicable for D, E, F mill only)
13. Respective feeder is off AND Pulverizer outlet temp is very high
14. Pulverizer ignition support required AND loss of Pulverizer ignition permit
15. Individual Elevation control supply 24 V DC failure will also trip the individual Pulverizer.

The Pulverizer is stopped under any one of the following conditions:

1. Pulverizer stop PB pressed under manual mode
2. Pulverizer stop under Auto stop programme
https://powerplanta2z.blogspot.com/2015/03/fsss.html 5/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

3. Pulverizer Trip.

v RAW COAL FEEDER AND FEEDER OUTLET DAMPER

Feeder outlet Damper will be opened if all the following conditions are satisfied
1. RC Feeder open PB pressed AND Pulverizer ON
OR
2. Feeder start command available under Pulv Auto start programme

Feeder outlet Gate will be closed under any one of the following conditions:

1. Pulverizer Trip condition present

2. Pulverizer fire fighting / inert command present
3. Close PB Pressed AND Feeder is off
4. Feeder is off AND stop feeder under Pulverizer Auto stop sequence present

Raw coal Feeder will be started if all the following conditions are satisfied

1. MFT not present

2. Feeder local / Remote switch in Remote position
3. 415 V AC supply available for feeder motor control
4. Elevation Logic power supply 24 V DC available
5. Pulverizer is ON
6. The following conditions are not present
RC Feeder outlet damper open AND PA General shut off damper open
OR
Stop Feeder auto
7. Pulv Ready AND Feeder feeder speed demand is minimum AND Hot air gate open AND
RC Feeder outlet damper open AND PA General shut off damper open AND starts
Feeder auto
OR
RC Feeder outlet damper open AND PA General shut off damper open
AND
RC Feeder start PB depressed AND Pulverizer manual mode.

v HOT AIR GATE

Hot air Gate will be closed under any one of the following conditions :
1. Pulv is off
2. Elev 24 V DC is not available
3. Hot air gate close PB pressed under manual mode for more than 30 secs
4. Auto Pulv unsuccessful start for more than 30 secs
5. Feeder is off for more than 30 secs
6. Close Hot air gate under Auto Pulv programme for more than 30 secs
7. Pulv outlet temp more than 94 degree C for more than 30 secs AN Hot air gate is not in closed position.

v PULVERIZER SHUTDOWN
When manual pulverizer control mode is selected, manual shutdown of a pulverizer is accomplished as follows
v Start the associated oil elevation if it is not in service
v Reduce the Feeder speed to minimum
v Close the Hot air gate
v When the pulv outlet temp is reduced to below 49.5 degree C then shutdown the feeder
v Allow the Pulv to run 2 minutes to ensure that it is totally empty of coal, then shutdown the Pulv.
v The respective PA Fan is stopped and close PA General S/O damper.

When Auto pulverizer control mode is selected, Auto shutdown of a pulverizer is accomplished as follows:
1. Pulverizer Auto shutdown command is given, the following events will occur:
https://powerplanta2z.blogspot.com/2015/03/fsss.html 6/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

v The ‘Auto stop memory’ signal is established and the ‘Auto start memory’ is reset.

v If the associated Pulv ignition permissive not satisfied, an ‘auto start support ignition energy’ command is established.
v A 10 minutes ‘elevation stop’ counting is started.

2. When the support ignition time has expired and the pulv ignition permissive is satisfied, the following events will occur:

v The Feeder demand will be minimum. The feeder speed will be reduced.
v Auto close Hot air Gate .

3. When the Hot air Gate closed and the pulv outlet temp is reduced to below 49.5 degree C then shutdown the feeder. Once
the feeder is off, ‘Feeder Auto stop’ command will close feeder outlet damper.
4. When the Pulv is off and ‘ Auto Pulv Stop’ condition present, which will initiate PA Fan ‘Auto Stop’ pulse and PA Fan
will be stopped.
5. The associated oil elevation can be shutdown when the furnace and boiler conditions have established.
When the 10 minutes ‘elevation stop’ count period expires, an ‘unsuccessful elevation shut down’ signal will be sent to the
alarm if any of the following conditions exist:
1. The Pulverizer is ON
2. The Feeder is ON
3. The Hot air Gate is not closed
4. The Hot PA Fan is ON.

v OIL ELEVATION SHUTDOWN

The oil elevation can be shutdown in either ‘pair mode’ or ‘elevation mode’ manually. When all feeders are off AND
associated Pulv of the oil elevation is in manual mode then ‘Pair mode’ is selected. If Feeder is associated with the oil elevation
is ‘proven’ ON, the elevation mode is selected.
v HEAVY OIL SHUTDOWN
v The Heavy oil Elevation can be removed from service on a pair basis if adjacent feeder is not in service. Pressing the
associated elevation PAIR STOP push button (for corners 1 & 3 or corner 2 & 4) will initiate a 375 secs stop time to shut
down and scavenge the associated of Heavy oil guns.
When H.O v/v is fully closed and the atomizing steam v/v has remained open, the scavenge v/v opens. When scavenge v/v lift
off from close position, HEA Rod is advanced and sparks for15 secs. At the end of the 5 minutes scavenge period, the
atomizing v/v and the scavenge v/v are closed.

For LIGHT OIL elevation (applicable for AB), the shut down procedure is similar of HEAVY OIL SHUT DOWN.

v BOILER TRIP

A BOILER TRIP command stops all fuel inputs by tripping all the Pulverizers, all the feeders and oil guns. A Boiler trip
command is initiated by any one of the following conditions is present.
1. Drum water level very low for more than 5 secs.
2. Drum water level very high for more than 10 secs.
3. Both ID Fans off.
4. Both FD Fans off
5. Unit airflow is less than 30%.
6. Furnace pressure is very high.
7. Furnace pressure is very low.
8. Loss of all fuel trips.
9. Unit Flame failure.
10. Both emergency trips PB pressed.
11. Spare trip.
12. Loss of Reheat protection.
13. Loss of 220 V DC for more than 2 secs.
14. < Fire Ball and Loss of AC at any elevation in service.

v The Loss of Fuel Trip circuit becomes armed once any nozzle v/v lifts off from closed position in any elevation.
https://powerplanta2z.blogspot.com/2015/03/fsss.html 7/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

Once the trip ckt is armed, Loss of all fuel trips will occur if

All feeders are off

AND
HO Trip v/v is not open
OR
Elev. AB, CD, EF Back up trip OR All HO nozzle v/v closed
AND
LO Trip v/v not open OR Elevation AB all LO nozzle v/v closed

During light up and until any pulv. is in service at a fire condition, the flame scanners do not take part in the overall flame
failure protection system.

A fireball condition is established for coal firing when either or both the adjacent feeders are proven AND 2 out of 4-scanner
show flame.

An elevation voting for ‘no flame’ condition is as follows

ELEVATION A/B/C/D/E/F

Feeder A/B/C/D/E/F is not proven

OR
Elevation AB/CD/EF 3 out of 4 Fire ball scanners show no flame AND HO/LO 2 out of 4 nozzle v/v open
OR
Elevation AB/CD/EF started and loss of power.
v UNIT FLAME FAILURE

All elevation voting for ‘no flame’ as above, will cause a unit trip on Flame failure, provided the flame failure circuit is armed.
(The Flame failure circuit will be armed when any feeder is proven).

https://powerplanta2z.blogspot.com/2015/03/fsss.html 8/9
7/3/2019 FSSS | THERMAL POWER PLANT A-Z

Posted 8th March 2015 by powerplanta2z

0 Add a comment

Enter your comment...

Comment as: Google Accoun

Publish Preview

https://powerplanta2z.blogspot.com/2015/03/fsss.html 9/9