BOILER PURGE CONTROL

The following permissive must be met before boiler purge can take place.

All Pulverizer Primary Air On-off type dampers Closed
Both PA Fans stopped
Total Boiler Air Flow at Purge Rate
Either Forced Draft Fan Running and either Induced Draft Fan running.
Secondary Air Heater Running
All oil igniter group SSVs closed
Igniter oil header SSV closed
All oil burner SSVs closed
Oil header SSV closed
All Coal feeders stopped
All Pulverizer Swing Valves Closed
All Coal Pulverizers Stopped
All air register Dampers at Light-off Position
No MFT Trip Condition Present (excludes steam drum level low / high)
MFT relay tripped.
Open flow path to stack proven.

Once these permissive met and continuous purge air flow rate maintained, a purge timer will
start & continue for required Purge period and indicate for PURGE COMPLETE

MASTER FUEL TRIP

MFT INPUT:
Steam Drum Level Not Low Low
Steam Drum Level Not High High
Main steam temperature Not High High
Furnace Pressure Not High-High
Furnace pressure Not Low Low
Total Boiler Air Flow less Than Minimum
Any Forced Draft Fan Running (Instantaneous)
Any Induced Draft Fan Running (Instantaneous)
Boiler Control System OK
Burner Management System OK
MFT Relay System Energized (Instantaneous)
MFT Switch Not Activated from field hardwired,
MFT Pushbutton Not Activated (software)
Black furnace trip
All igniter group successfully Shutdown or tripped.
All Pulveriser groups successfully shutdown or tripped.
All oil burners successfully shutdown or tripped.

MFT OUTPUT:

When the MFT is activated, the following fuel input devices shall be simultaneously DE
energized/ closed :
Igniter oil Header Safety Shutoff Valve (SSV)
All Individual Igniter Group Ignition Transformers
All Individual Igniter Group Oil SSVs
All Individual Igniter Group Atomizing SSVs
All Individual Igniter Group Clearing SSVs
Main oil Header Safety Shutoff Valve (SSV) (& open recirculation valve)
All Individual Burner Oil SSVs
All Individual Burner Atomizing SSVs
All Individual Burner scavenging SSVs
All Coal Feeders
All Coal Pulverizers
All PA isolation dampers at mill inlet
All Individual Pulverizer Group Swing Valves
Boiler Control System (DCS) (To close Primary Superheat Block Valve, Secondary
Superheat Block Valve, set the fuel control to minimum position, and Stop both PA fans,
Stop seal air fans and close the PA Fan dampers)

BOILER FIRING PERMISSIVES:
Purge Complete
Flame Scanner Cooling air pressure not low
Ignitor cooling air pressure not low
Total boiler air flow greater than or equal to 25 percent
No Furnace Firing Inhibit Present

The Furnace Firing Inhibit is activated for one minute duration when any of the following
condition occurs:
Trip of any igniter group when the associated Pulverizer Group Main (coal) Fuel
Monitoring Mode is not activated. (See Pulverizer Group Start Sequence section of
this Document) AND Boiler Load is less than 50%
Start of any Igniter Group AND Boiler load is less than 50%
Start of any Oil Burner AND Boiler load is less than 50%
Any oil burner trip AND Boiler load is less than 50%
Start of any coal feeder
Any pulverizer group Emergency Trip
Start of any Igniter Group
The Furnace Firing Inhibit is activated for 15 seconds duration when boiler load is greater
than 50% & any of the following condition occurs:
Trip of any igniter group when the associated Pulverizer Group Main (coal) Fuel
Monitoring Mode is not activated.
Start of any Igniter Group.
Start of any Oil Burner.
Any oil burner trip.


FLAME MONITORING AND TRIPPING:

Ignitor in a group of three and each flame must be healthy after ignitor group
command.
For oil burners individual burners flame must be healthy.
For coal flame 2/6 logic or ignitor in service.
BURNER AIR SLIDE (AIR REGISTER) DAMPER CONTROL:

Each burner sliding air dampers is positioned by a 4-20 mA DC Linear Pneumatic Actuator &
Burner sliding air dampers position transmitter. The Burner Management System includes
analog input and analog output interface devices.

Cooling Position: provides cooling air while the burner is out of service.

Light-off Position: During igniter operation and during pulveriser group / oil burner is
in start-stop sequence.

Firing Position
Sliding air dampers has two firing positions viz. Coal firing position and Oil firing position. Oil
firing position is wide open than coal firing position. The BMS shall automatically position the
Burner Sliding Air Dampers to the firing positions when all of the following conditions occur:
Coal Firing Position
Oil Firing Position

Allow Burner Sliding Air Damper Positioning
.
All Burner Sliding Air Dampers are locked in last position for 2 minutes whenever MFT
activated and total Boiler Air Flow greater than or equal to 30 percent

All Burner Sliding Air dampers are locked in last position for 5 minutes whenever MFT
activated and total Boiler Air Flow less than 30 percent.

All Burner Sliding Air Dampers are locked in last position for 1 minutes and a 15-minute
when Natural Draft is required when the Both Induced Draft Fans or Forced draft fans
stopped within 5 minutes after a MFT is activated
.
.
IGNITER OIL HEADER SAFETY SHUTOFF VALVE:

The Igniter Header control logic shall include the opening and closing of the safety shutoff
valve (SSV) for the igniter oil header which results supply of LDO to all igniter groups. The
igniter oil header contains three (3) pressure transmitters, one no. safety shut-off valve (SSV).

When the following permissives are met, operator may open igniter oil header SSV via
Operator Station (OS):
Boiler Firing Permissive Satisfied
Igniter Oil Header SSV Closed
All Individual Igniter Group Oil SSVs Closed
Igniter Oil Header SSV not Commanded (interlocked) Closed
Igniter Oil Header Not Tripped
The operator can close the Igniter Oil Header SSV anytime (via OS), if it is in the open
position. The Igniter Oil Header SSV shall be interlocked to remain in closed condition
automatically when any of the following conditions occur:
Operator Activated the Close Igniter Oil Header SSV Pushbutton (via OS)
Igniter Oil Header Trip Activated.
MFT Activated
Igniter Oil Header Trip shall be activated when any of the following conditions occur:
Igniter Oil Header pressure low .
Any Igniter Group Flame Not detected and Associated Igniter Group SSV Failed to
Close
Igniter Atomizing Media Header Pressure Low.
Igniter Oil Header SSV Failed To Close (10 second delay)

IGNITER GROUP CONROL:
Igniter group AF -- elevation A front side.
Igniter group BF -- elevation B front side.
Igniter group CF -- elevation C front side.
Igniter group DF -- elevation D front side.
Igniter group AR -- elevation A rear side.
Igniter group BR -- elevation B rear side.
Igniter group CR -- elevation C rear side.
Igniter group DR -- elevation D rear side.

Igniter Group Tripped/Stop
An igniter group trip shall be generated if any of the following occurs during starting, shutdown
/ cleaning, or when the igniter group is in service :
Igniter group atomizing pressure not adequate (low) (5 second delay)
Igniter group SSV failed to close (10 second delay)
Igniter group SSV failed to open (10 second delay)
Igniter group atomizing air SOV failed to close (10 second delay)
Igniter group atomizing air SOV failed to open (10 second delay)
Igniter group purge SOV failed to open (10 second delay)
Igniter group purge SOV failed to close (10 second delay)
Igniter group any flame failure (any associated flame not detected and igniter group
trial for ignition period completed)
Igniter group emergency stop pushbutton activated
Associated Pulveriser group trips on emergency
operator may stop an igniter group anytime it is in the process of starting or in service.
Pulverizer group emergency trip pushbutton pressed (via OS)
Operator activated the stop igniter group pushbutton (via OS)
Pulverizer group start sequence requires to stop associated igniter groups.\
MFT activated
Any oil burner sequence requires stop igniter.

Clearing (Cleaning) the Igniters:
Once the Igniter group is stopped due to any of the above mentioned conditions, it closes
igniter Oil SSV immediately. However atomizing air SSV continues in open condition for
clearing cycle unless igniter group is tripped.


OIL BURNER HEADER SAFETY SHUTOFF VALVE:

The oil burner header (Note: wherever mentioned header implies to common header to
burners) control logic shall include the opening and closing of the safety shutoff valve (SSV)
for the oil burner.

The operator may open, via Operator Station (OS), the oil burner header SSV when the
following permissives are met:
Oil Burner firing permissives satisfied
Oil burner header SSV closed
All individual oil burner SSVs closed
Oil burner header SSV not commanded (interlocked) closed
Oil burner Header recirculation valve closed.
The operator may close (via OS) the oil burner header SSV anytime it is in the open position.
The oil burner header SSV shall be interlocked closed when any of the following conditions
occur :
Operator activated the close oil burner header SSV Pushbutton (via OS)
Oil burner header trip activated
MFT activated
Differential pressure between oil & atomizing header very low when header SOV not
closed or any oil burner SSV not closed (7 second delay)
An oil burner header trip shall be activated when any of the following conditions occur (
i.e. all
the running oil burners will trip):
Oil burner header pressure low with oil burner header SSV not closed OR any Oil
Burner SSV Not Closed (7second delay)
Oil burner header temperature low with oil burner header SSV not closed OR any Oil
Burner SSV Not Closed (7second delay)
Any oil burner flame not detected and associated oil burner SSV failed to close
Oil burner header SSV failed to open (7 second delay)
Oil burner header SSV failed to close (7 second delay)

OIL BURNER HEADER RECIRCULATION SHUTOFF VALVE :

Once main oil header SSV is confirmed closed (with delay of 2 seconds) then recirculation
SSV is opened if any of the following conditions are active:
Operator open the recirculation SSV through command on OS.
All oil burner SSVs closed.
Master fuel trip activated
Main oil header SSV close required.
Recirculation SSV shall close automatically if the main header line SSV is commanded open /
not in closed condition. Also, if MFT is not activated then operator can manually close the
recirculation valve.

OIL BURNER CONTROL:
The oil burners are controlled individually. Initiating an oil burner start or stop sequence will
initiate the corresponding igniter group start sequence. The igniter group for a particular
burner group must be successfully lit before main fuel for a particular burner can be fired.

The burner oil firing permissives are satisfied when all of the following conditions occur :
Boiler firing permissives satisfied.
Burner oil header SSV commanded to open and is confirmed open.
Atomizing steam common header pressure not low (2oo3)
Burner oil header trip reset
Any FD fan Running
Oil burner gun retracted Oil burner trips reset
Oil burner firing selected
Igniter group ready to start or in service
Oil burner firing permissives satisfied
Oil burner atomizing SOV closed and corresponding scavenging SOV closed Oil
burner SSV closed
Flame scanner permissive satisfied
Pulverizer Isolated
Oil Burner clean
Oil burner not in Start / Running sequence.
Burner main flame not detected OR unit load greater than 60% OR Igniter group
successfully lit
After all permissives are satisfied, a Burner Ready indication is generated and the operator
can start the burner. The following sequence will proceed automatically.
Open PC pipe (nozzle) cooling air valve and confirm it is open
Set burner secondary air register at light-off position
Start igniter group (if not in service)
Confirm igniter group in service
Insert Burner Oil Gun and Confirm Insertion
Open Oil Burner atomizing steam SOV and confirm that it is open
Open the oil burner SSV and confirm that it is open
Begin burner trial for ignition (5 seconds) after fuel actually begins to enter the
furnace
Oil burner successfully lit.
Position burner secondary air register to oil firing position
Stop the corresponding igniter group when a time of Five minutes is elapsed after
start memory for oil burner is set. Additionally Stop the corresponding igniter group
immediately when all three oil burners are in service.

A given oil burner is considered successfully lit when all of the following conditions are met :
No Oil burner trip condition present
Trial time (5 second elapsed) for ignition complete
Burner flame detected
Burner oil gun (assembly) inserted
Burner oil SSV open
Burner atomizing SOV open
Burner PC pipe cooling air valve open.

Oil Burner Trip:

If any of the following conditions occur, an oil burner trip shall be generated
Operator pressed the oil burner emergency stop pushbutton.
Igniter group stopped during oil burner gun (scavenging) clearing
Oil burner flame failure (burner flame NOT DETECTED AND TRIAL TIME for ignition
timed out)
Oil burner SSV failed to open (10 sec delay)
Oil burner SSV failed to close (10 sec delay)
Oil burner failed to insert (10 sec delay)
Oil burner failed to retract (10 sec delay)
Oil burner atomizing SOV failed to open (10 sec delay)
Oil burner atomizing SOV failed to close (10 sec delay)
Oil burner scavenging SOV failed to open (10 sec delay)
Oil burner scavenging SOV failed to close (10 sec delay)
Oil burner start / stop sequence requires corresponding igniter group and the igniter
group failed to start
Burner PC pipe cooling air valve failed to close
Burner PC pipe cooling air valve failed to open
Oil header steam DP low AND oil burner atomizing valve open
Burner oil valve open & Oil header SSV close required
When an oil burner trips or a master fuel trip occurs, all of the following conditions will occur.
In this case, oil gun scavenging sequence is not initiated automatically.
Close the oil burner oil SSV
Close the oil burner atomizing SOV
Close the oil burner scavenging SOV

Stopping the Oil Burner:

The operator can stop an oil burner at any time by activating the oil burner stop pushbutton.
The stop oil burner command shall initiate the following sequence automatically and stop the
burner. This sequence is also termed as Scavenging (Oil gun cleaning) sequence.
Start igniter group.
Allow 15 seconds to confirm igniter group is in service
Close the oil burner SSV and confirm that it is closed
Set burner air register to light-off position
Open the oil burner scavenging SOV (if scavenging cycle is not blocked)
Hold for 3 minutes for scavenging the burner oil gun
Close the oil burner atomizing steam SOV and confirm that it is closed
Close oil burner scavenging SOV and confirm that it is closed
Retract burner oil gun.
Close the PC pipe cooling air valve.
Stop the corresponding igniter group when duration of Five minutes is elapsed.
after Burner Stop memory set. Additionally Stop the corresponding igniter group
immediately when all oil burners are successfully shutdown.

Scavenging the Oil Burner:
The oil gun is considered dirty as soon as the oil SSV is opened during burner start sequence.
During stop sequence of oil burner, the scavenging cycle is performed in auto sequence, after
completion of which the oil gun is considered as clean.
The oil burner scavenging cycle can be initiated when all of the following conditions occur :
Oil burner dirty
Oil burner scavenging cycle not blocked
Operator activated the oil burner stop pushbutton via the DCS
When the operator initiates the oil burner scavenging cycle via the oil burner stop pushbutton,
the following sequence will occur:
Start igniter group
Allow 15 seconds to confirm igniter group is in service
set burner air register to light-off position
Insert burner oil gun if it is not inserted.
Open the oil burner scavenging SOV
Hold for 3 minutes to scavenge (purge) the Burner Oil gun
Close the oil burner atomizing steam SOV and confirm that it is closed
Close oil burner scavenging SOV and confirm that it is closed
Retract burner oil gun
Close the PC pipe cooling air valve
Stop the corresponding igniter group when all oil burners are successfully
shutdown or tripped and the Maintain igniter group memory is reset.
A burner oil gun (scavenging) cleaning cycle is blocked when any of the following conditions
occur:
Oil burner tripped
Master fuel trip activated
Operator pressed the start oil burner pushbutton (momentary)
Oil burner header steam to oil differential pressure low
Oil burner gun retracted
The burner oil gun (scavenging) clearing cycle blocked memory is reset when any of the
following conditions occur:
Oil burner start sequence running / Burner lit.
Oil burner trip reset.
The oil burner will not retract automatically when the oil burner scavenging (clearing) cycle is
blocked. However, the operator can retract the oil burner by pressing the Retract Oil Burner
pushbutton (OS) when all of the following conditions are satisfied
Oil burner oil SSV closed
Oil burner atomizing SOV closed
Oil burner scavenging SOV closed
Oil burner scavenging blocked for more than 30 seconds.
Once Oil gun is retracted, the PC pipe cooling air valve shall close automatically.
A burner is successfully shutdown when all of the following conditions occur:
Oil burner retracted
Oil burner SSV closed
Oil burner Clean
Oil burner atomizing SOV closed
Oil burner scavenging / clearing SOV closed

OIL BURNER SEQUENTIAL START IN AUTO:
Elevation all (six) Oil Burner can be started in auto sequence with operator intervation.
This facility is provided to meet the boiler demand in short period of time.



PULVERIZER GROUP CONTROL:

There are four pulverizer groups (A, B, C and D), all burners in a pulverizer group are
controlled as a group. Each burner is equipped with a swing valve. All six (6) swing valves
associated with a pulverizer group shall be opened and closed at the same time. Starting and
stopping individual burners in a pulverizer group is not permitted.
A remotemanual isolation valve (pneumatically operated) is installed in each burner line (coal
pipe) as close to the furnace as practicable, which is operated by operator when required for
maintenance.

The pulverizer seal air fan, PA fan(s)
and lube oil pump should be started as the initial steps before placing the pulverizer group in
service.

A pulverizer group can be operated in a manual or automatic sequence control mode.

Pulverizer Group Equipment Permissives
Pulverizer not tripped
Coal Feeder not Tripped
MFT activated
Pulverizer Group Emergency trip activated
PA Flow Tripped(PA flow isolation damper is not tripped, Either PA fan running)

Operator activated the pulverizer group stop sequence pushbutton (via OS)

Pulverizer lube oil temperature above minimum & less than maximum
Pulverizer lube oil pump running
Pulverizer lube oil pressure not low low
All PC pipe isolation valves are open
Pulverizer Lube Oil System Parameter healthy.
All oil burners SSV closed & nozzle / purge air valve closed.
Coal feeder equipment permissive satisfied.

Pulverizer Group Start Sequence
An operator initiated (via OS) START pulverizer Group A command shall activate the following
start sequence
SET the pulverizer group demand to minimum.
SET Burner group Sliding Air dampers to Light-off position.
START associated lgniter group AND confirm igniter group in-service.
START pre-start inert (required when the pulverizer was stopped prior to completing a
normal cleaning cycle,
CONFIRM pre-start inert is completed..
OPEN pulverizer yoke Seal Air Valve and confirm that the Valve is open
OPEN pulverizer roll Wheel Seal Air valve and confirm that the valve is open & seal air
pressure is adequate.
OPEN coal feeder seal air valve and confirm that the valve is open & seal air pressure
is adequate.
OPEN pulverizer primary air On-off damper and confirm that the damper is open
OPEN pulverizer group swing valves (quantity 6) and confirm that the valves are open
Wait 10 seconds to Establish primary air flow.
OPEN coal feeder inlet valve and confirm that it is open (part of coal feeder equipment
permissive)
OPEN coal feeder discharge valve and confirm that the valve is open
START pulverizer motor.
Wait 10 seconds for pulverizer motor to ramp up to speed
Confirm coal feeder demand at minimum
START coal feeder and confirm that feeder is running
RELEASE primary air hot and tempering dampers to automatic temperature control
Wait 3 minutes for initial coal flame stabilization
SET burner Group sliding Air damper to firing position (Qty. 6)
RELEASE Pulverizer group demand to Automatic Control
Wait 5 minutes for final coal flame stabilization
STOP associated Igniter Groups when all of the following conditions occur (operator
action only) :
Unit load greater than 25 percent
Pulverizer in Auto mode.
Pulverizer group A in service
Secondary air temperature greater than 149degC
Maintain igniter group mode de-activated.
Pulverizer final coal flame stabilization period complete.

Pulverizer Group stop sequence:

An operator initiated STOP Pulverizer group A command (via OS) shall activate the following
sequence :
START associated igniter Group A AND confirm igniter Group A IN-SERVICE
REDUCE Pulverizer group A demand to MINIMUM
CLOSE primary hot air damper AND confirm primary tempering air damper NOT
CLOSED
WAIT 5 minutes for Pulverizer A cooling
STOP coal feeder A AND confirm coal feeder stopped
SET Burner Group sliding air dampers to light-off position
CLOSE coal feeder A discharge valve and confirm that it is closed
WAIT 10 minutes for initial pulverizer A cleaning
STOP pulverizer A AND confirm pulverizer stopped
Maintain PA flow unit pulverizer A outlet temperature decreases below 60 Deg C
for greater than 2 minutes
CLOSE all pulverizer group a swing valves (quantity 6)
STOP primary air flow (CLOSE the primary air on-off type damper)
STOP associated Igniter group A (only if Maintained Igniter Group de-activated)
SET Burner sliding air dampers to COOLING position (operator action when boiler
load conditions and register permissives are satisfied)

Pulverizer group A is interlocked to stop when any of the following conditions occur
Pulverizer A Tripped
Coal Feeder A Tripped
Master Fuel Trip activated
PA Flow A Tripped
Pulverizer Group A Emergency Trip activated
Operator activated the stop pulverizer group A pushbutton (via OS)


Coal Feeder Start / Stop:

Coal feeder is considered READY to start when all of the following permissives are
SATISFIED
Boiler firing permissives satisfied
Coal feeder A NOT TRIPPED
Pulverizer group emergency trip reset
Pulverizer group demand at MINIMUM
Pulverizer RUNNING Greater than 10 seconds
Coal feeder inlet valve OPEN
Coal Feeder outlet not plugged
Coal feeder in remote mode
Coal feeder seal air pressure greater than MINIMUM
Coal feeder discharge gate open
Associated igniter group in-service
Pulverizer group burner sliding air damper at light-off position.

The coal feeder trip shall be generated when any of the following conditions occur:

Coal Feeder running and coal feeder discharge valve closed
Coal Feeder commanded to start and greater than 1 Burner swing valve closed
Coal feeder failed to start (10 second delay)
Coal feeder failed to stop (10 second delay)
Coal feeder commanded to start and discharge chute plugged (2 second delay)
Coal feeder commanded to start and local mode selected
Coal feeder commanded to start and either igniter group not in-service or no coal on
belt for greater than 2 minutes