Boiler Interlock And Protection 221016
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Boiler Interlock And Protection Manish Dhruw Asst Manager 14843 p-540
Boiler interlock and protection
Boiler Interlock - A Boiler Interlock is an arrangement of heating controls. It ensures the boiler does not fire when there is no demand for heat. Protection of boiler – Boiler protection are provide to detect the abnormal condition by constantly measuring the various parameter under normal and faulty condition. If any abnormality happened trip the boiler to prevent from major damage. Need
◦ ◦ ◦ ◦
To To To To
of Interlocks & Protection
avoid avoid avoid avoid
operational faults equipments damage. accidents to individuals. system disturbances
In case of MFT Trip Master Fuel Trip - it produces trip signal for fuel systems from operation , then trip the boiler out of service away from danger. this relay needs many will failure. be found 9. Unit flame conditions 1. Both ID to fanoperate trip. , these• conditions at the following points. • 10. Loss of fuel. 2. Both FD fans trip. • 11. Loss of scanner 3. Emergency manual cooling air (Scanner air trip. pressure<2 KPa with 5 4. Turbine tripped and min time delay). HPLP by not • 12. Both APH tripped. opened (RH protection • 13. Oil burner light off act). 5. Drum level low low failed. low (<-325mm with 5 sec delay). • Other than MFT 6. Total air flow<30%. • 1. MS
Boiler
Interlocks cum protections
1. If one ID fan trips, one FD fan will trip in the same sequence. 2. If one FD fan trips, one ID fan will trip in the same sequence. 3. If one APH trips, one ID fan, one FD fan and one PA fan will trip in the same sequence. 4. In case of GCB opening, top elevation mill or non adjacent mill will trip. 5. If drum level≥200 mm, EBD will open. 6. If drum level≤150 mm, EBD will close. 7. Feed water flow<50 TPH, Economiser recirculation MOV will open. 8. Feed water flow>80 TPH, Economiser recirculation MOV will close. 9. If superheated steam pressure is higher than 14.86 MPa ERV will open and if pressure is lower than the value ERV will close (if kept in service).
Other Protections 1. Boiler drum pressurea) Higher than 17.24 MPa LHS safety valve will lift and it will reset @ 16.35 MPa. b) Higher than 16.74 MPa RHS safety valve will lift and it will reset @ 16.21 MPa. 2. Superheated steam pressurea) Higher than 15.29 MPa, LHS safety valve will lift and it will reset @ 14.765 MPa. b) Higher than 15.2 MPa, RHS safety valve will lift and it will reset @ 14.747 MPa. 3. CRH steam pressurea) Higher than 3.058 MPa, LHS safety valve will lift and it will reset @ 2.947 MPa. b) Higher than 2.963 MPa, RHS safety valve will lift
Alarm
Drum level 1. Level>125 mm: high priority alarm. 2. Level>-125 mm: high priority alarm. 3. Level>250 mm: emergency priority alarm. 4. Level>-250 mm: emergency priority alarm. Furnace pressure 1. Pressure>30 mm of H2O: high priority alarm. 2. Pressure>-30 mm of H2O: high priority alarm. 3. Pressure>50 mm of H2O: emergency priority alarm. 4. Pressure>-50 mm of
• • • • • • •
• • •
MS & RH Temperature 1. MS temperature>5450C: high priority alarm. 2. MS temperature>5500C: emergency priority alarm. 3. RH temperature>5450C: high priority alarm. 4. RH temperature>5500C: emergency priority alarm. Others 1. APH flue gas inlet temperature<3000C: high priority alarm. 2. O2<1: high priority alarm. 3. O2 zero: emergency priority alarm. 4. Furnace DP≥90 mm of
ID Fan interlock & protection
1. No ID fan A/B converter/ device fault. 2. No ID fan protection acted. AND 3. ID fan A/B inlet & outlet damper closed. 4. ID fan IGV in minimum position. 5. APH A/B flue gas inlet & outlet damper open. 6. APH A/B running 1. ID fan A/B breaker protection acted. Or OR 2. BMS trip ID fan A/B. Or 3. FD fan A/B tripped. Or 4. APH A/B tripped. Or 5. ID fan A/B temperature protection
e Interl ock:
TRIP enabl e Interl ock:
ALARM 1. Fan/ motor bearing temperature≥750C: high priority alarm. 2. Fan/ motor bearing temperature≥800C: emergency priority alarm. 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm. 4. Fan bearing vibration≥11mm/sec: emergency priority alarm. 5. Motor winding temperature≥1100C: high priority alarm. 6. Motor winding temperature≥1200C: emergency priority alarm TRIP 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60sec time delay). 2. Fan/ motor bearing temperature≥900C (with 60 sec time delay).
FD Fan interlock & protection
1. No FD fan A/B converter/ device fault. 2. No FD fan protection acted. Start 3. FD fan A/B outlet damper closed. enable 4. FD fan IGV in minimum position. 5. APH A/B flue gas inlet & outlet damperInterlo AN ck: open. D 6. APH A/B running. 7. ID fan A/B running. 1. FD fan A/B breaker protection acted. Or 2. BMS trip FD fan A/B. Or 3. ID fan A/B tripped. Or OR 4. APH A/B tripped. Or 5. FD fan A/B temperature protection
TRIP enable Interlo ck:
ALARM 1. Fan/ motor bearing temperature≥750C: high priority alarm. 2. Fan/ motor bearing temperature≥800C: emergency priority alarm. 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm. 4. Fan bearing vibration≥11mm/sec: emergency priority alarm. 5. Motor winding temperature≥1100C: high priority alarm. 6. Motor winding temperature≥1200C: emergency priority alarm. TRIP 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60sec time delay). 2. Fan/ motor bearing temperature≥900C with 60 sec
PA Fan interlock & protection
1. No PA fan A/B converter/ device fault. 2. No PA fan protection acted. 3. PA fan A/B outlet damper closed. AND 4. PA fan IGV in minimum position. 5. APH A/B flue gas inlet & outlet damper open. 6. APH A/B running. 7. ID fan A/B running. 8. FD fan A/B running. 9. No boiler trip command. 1. PA fan A/B breaker protection acted. Or 2. MFT trip PA fan A/B. Or • 3. ID fan A/B tripped. Or 4. FD A/B tripped. Or 5. PA fan A/B temperature protection acted.
OR
Interl ock
Trip enabl e Interl ock:
ALARM 1. Fan/ motor bearing temperature≥75 0C: high priority alarm. 2. Fan/ motor bearing temperature≥80 0C: emergency priority alarm. 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm. 4. Fan bearing vibration≥11mm/sec: emergency priority alarm. 5. Motor winding temperature≥110 0C: high priority alarm. 6. Motor winding temperature≥120 0C: emergency priority alarm.
TRIP 1. Motor winding temperature≥130 0C (2 out of 6 temperatures with 60 sec time delay). 2. Fan/ motor bearing temperature≥90 0C with 60 sec time delay. 3. Fan bearing vibration≥11mm/sec with 60 sec time delay. 4. PA fan motor protection (over current, earth fault, negative sequence, phase fault etc) acted. 5. MFT trip PA fan. 6. ID fan/ FD fan A/B trip to PA fan A/B trip. 7. PA fan running and fan discharge damper closed.
Seal air fan interlock & protection
1. No fan converter/ device/ breaker fault. 2. Any one PA fan running. 3. Fan IGV in minimum position. 4. In case of one fan running & other fan standbya) If running fan getting tripped due to any protection acting then stand by fan will start in interlock if selected. b) If seal air pressure becomes low (<6 KPa), then standby fan will start by interlock. 4. During unit start up fan start enable will come with the start of any PA fan if selected in fan auto start interlock. **Command will go to Seal air fan IGV for 60% opening in auto with
e interl ock:
• AND
• OR
1. Seal air fan current>200 Amp: high priority alarm. 2. Seal air fan current>260 Amp: emergency priority alarm. 3. Seal air discharge pressure<800: high priority alarm. 4. Seal air discharge pressure<600: emergency priority alarm. 1. Seal air fan current≥ 284Amp. 2. Both PA fans stopped/ tripped (fan trip after 2Sec).
ALARM
TRIP
Scanner Air Fan Interlock Protection
1. No motor or breaker protection acted. 2. Fan is in remote. 3. In case of one fan is running and the other is in stopped conditiona) By interlock input if one fan is stopped/ tripped, standby fan will start in auto. b) If scanner air header pressure<2 KPa for 5 sec, then standby fan will start in auto by interlock input. 1. Scanner air header pressure< low switch acting: emergency
AND
Start Enable Interlo ck
Alarm
Trip
Mill Interlock & Protection
1. No breaker/ motor protection acted. 2. Lube oil pressure normal for > 5 minutes. 3. No MFT acted. AND 4. Boiler drum pressure>3.4 kg/cm2. 5. Secondary air temperature>1770C. 6. Total air flow<40% (230TPH). 7. MDVs are open. 8. Mill outlet temperature<1150C.
Start Enable Interlock
1. Feeder trip and no mill ignition permit. 2. MFT. 3. MDVs closed. 4. Lube oil pressure low (2 out of 3 lube oil pressure
AND
1. Mill lube/ hydraulic oil tank temperature>750C: high priority alarm. 2. Mill lube oil thrust pad oil temperature>600C: high priority alarm. 3. Mill lube oil thrust pad oil temperature>700C: emergency priority alarm. 4. Mill motor front/ rear bearing temperature>750C: high priority alarm. 4. Mill motor winding temperature>1000C: high priority alarm. 5. Mill outlet, roller bearing temperature>900C: high priority alarm. 6. Mill current>60 amp: high priority alarm. 7. Mill inlet PA flow< 50 TPH: high
Alarm
1. Mill motor protection (over current, earth fault, negative sequence, phase fault etc) acted. 2. MFT trip mills. 3. MDVs closed trip mill (2 out of 4 MDVs). 4. Mill lube oil pressure low (2 out of lube oil pressure
Trip
Coal Feeder Interlock & Protection
Start enable Interlock: 1. No breaker or motor protection acted. 2. Respective mill ignition permit. 3. Feeder speed (VFD command) minimum. 4. No mill trip command. 5. Feeder is in remote.
Start Enable
AN D
1. 2. 3. 4.
Mill trip/ emergency stop. MFT. Feeder running and no coal. Mill outlet
OR
Interlo ck
Stop/Trip Enable Interlo ck:
1. Belt deviation of feeder switch act: high priority alarm. 2. No coal switch act: high priority alarm. 3. Coal jam switch act: low priority alarm. 4. Feeder cleaner motor fault: low priority alarm. 5. Coal flow zero: low priority alarm.
Alar m
Trip
1. Mill trip to feeder trip. 2. MFT to feeder trip. 3. Feeder motor/ breaker protection acted.
Mill Lub Oil Pump Interlock & Protection
1. No breaker or motor protection acted. 2. LOP is in remote. 3. Oil pool temperature of lube oil>600C.
1. Oil pool temperature of lube oil<450C. 2. After LOP starting if oil pool temperature of lube oil<450C and mill not running (30 mins time delay). 3. After mill stopping after 4 hrs time delay stop command will go for LOP.
Start enable Interlo ck
AND
OR
Stop/tri p enable Interlo ck
1. Lube oil pump stopped: emergency priority alarm. 2. Lube oil pressure
: 750C high priority alarm. 4. Lube oil thrust liner sump temperature>: 600C high priority alarm. 5. Lube oil thrust liner sump temperature>: 700C emergency priority alarm. 1. LOP motor/ breaker protection acted. 2. Oil pool temperature of lube 0
Ala rm
Trip
APH Interlock & Protection
• • • • •
1. No breaker or motor protection acted. 2. APH is in remote. 3. Guide and bearing oil pump running for minimum of 300 sec (for U#2 APH).
AND
Interl ock
Stop/tr ip enabl e Interl ock:
1. APH flue gas inlet temperature<800C OR and fans (ID, FD & PA) are running. 2. For APH auxiliary motor, with the start of APH main motor trip command will Other Interlocks: go. 1. Start command will go for APH auxiliary motor (DC) with the tripping of APH main motor. 2. In case of APH main motor VFD getting byed due to any fault, APH main motor DOL supply will pick up. 3. For U#2 APHa) If APH /guide bearing temperature> 54 0C, lube oil pump will start.
a h T s nk
Boiler interlock and protection
Boiler Interlock - A Boiler Interlock is an arrangement of heating controls. It ensures the boiler does not fire when there is no demand for heat. Protection of boiler – Boiler protection are provide to detect the abnormal condition by constantly measuring the various parameter under normal and faulty condition. If any abnormality happened trip the boiler to prevent from major damage. Need
◦ ◦ ◦ ◦
To To To To
of Interlocks & Protection
avoid avoid avoid avoid
operational faults equipments damage. accidents to individuals. system disturbances
In case of MFT Trip Master Fuel Trip - it produces trip signal for fuel systems from operation , then trip the boiler out of service away from danger. this relay needs many will failure. be found 9. Unit flame conditions 1. Both ID to fanoperate trip. , these• conditions at the following points. • 10. Loss of fuel. 2. Both FD fans trip. • 11. Loss of scanner 3. Emergency manual cooling air (Scanner air trip. pressure<2 KPa with 5 4. Turbine tripped and min time delay). HPLP by not • 12. Both APH tripped. opened (RH protection • 13. Oil burner light off act). 5. Drum level low low failed. low (<-325mm with 5 sec delay). • Other than MFT 6. Total air flow<30%. • 1. MS
Boiler
Interlocks cum protections
1. If one ID fan trips, one FD fan will trip in the same sequence. 2. If one FD fan trips, one ID fan will trip in the same sequence. 3. If one APH trips, one ID fan, one FD fan and one PA fan will trip in the same sequence. 4. In case of GCB opening, top elevation mill or non adjacent mill will trip. 5. If drum level≥200 mm, EBD will open. 6. If drum level≤150 mm, EBD will close. 7. Feed water flow<50 TPH, Economiser recirculation MOV will open. 8. Feed water flow>80 TPH, Economiser recirculation MOV will close. 9. If superheated steam pressure is higher than 14.86 MPa ERV will open and if pressure is lower than the value ERV will close (if kept in service).
Other Protections 1. Boiler drum pressurea) Higher than 17.24 MPa LHS safety valve will lift and it will reset @ 16.35 MPa. b) Higher than 16.74 MPa RHS safety valve will lift and it will reset @ 16.21 MPa. 2. Superheated steam pressurea) Higher than 15.29 MPa, LHS safety valve will lift and it will reset @ 14.765 MPa. b) Higher than 15.2 MPa, RHS safety valve will lift and it will reset @ 14.747 MPa. 3. CRH steam pressurea) Higher than 3.058 MPa, LHS safety valve will lift and it will reset @ 2.947 MPa. b) Higher than 2.963 MPa, RHS safety valve will lift
Alarm
Drum level 1. Level>125 mm: high priority alarm. 2. Level>-125 mm: high priority alarm. 3. Level>250 mm: emergency priority alarm. 4. Level>-250 mm: emergency priority alarm. Furnace pressure 1. Pressure>30 mm of H2O: high priority alarm. 2. Pressure>-30 mm of H2O: high priority alarm. 3. Pressure>50 mm of H2O: emergency priority alarm. 4. Pressure>-50 mm of
• • • • • • •
• • •
MS & RH Temperature 1. MS temperature>5450C: high priority alarm. 2. MS temperature>5500C: emergency priority alarm. 3. RH temperature>5450C: high priority alarm. 4. RH temperature>5500C: emergency priority alarm. Others 1. APH flue gas inlet temperature<3000C: high priority alarm. 2. O2<1: high priority alarm. 3. O2 zero: emergency priority alarm. 4. Furnace DP≥90 mm of
ID Fan interlock & protection
1. No ID fan A/B converter/ device fault. 2. No ID fan protection acted. AND 3. ID fan A/B inlet & outlet damper closed. 4. ID fan IGV in minimum position. 5. APH A/B flue gas inlet & outlet damper open. 6. APH A/B running 1. ID fan A/B breaker protection acted. Or OR 2. BMS trip ID fan A/B. Or 3. FD fan A/B tripped. Or 4. APH A/B tripped. Or 5. ID fan A/B temperature protection
e Interl ock:
TRIP enabl e Interl ock:
ALARM 1. Fan/ motor bearing temperature≥750C: high priority alarm. 2. Fan/ motor bearing temperature≥800C: emergency priority alarm. 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm. 4. Fan bearing vibration≥11mm/sec: emergency priority alarm. 5. Motor winding temperature≥1100C: high priority alarm. 6. Motor winding temperature≥1200C: emergency priority alarm TRIP 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60sec time delay). 2. Fan/ motor bearing temperature≥900C (with 60 sec time delay).
FD Fan interlock & protection
1. No FD fan A/B converter/ device fault. 2. No FD fan protection acted. Start 3. FD fan A/B outlet damper closed. enable 4. FD fan IGV in minimum position. 5. APH A/B flue gas inlet & outlet damperInterlo AN ck: open. D 6. APH A/B running. 7. ID fan A/B running. 1. FD fan A/B breaker protection acted. Or 2. BMS trip FD fan A/B. Or 3. ID fan A/B tripped. Or OR 4. APH A/B tripped. Or 5. FD fan A/B temperature protection
TRIP enable Interlo ck:
ALARM 1. Fan/ motor bearing temperature≥750C: high priority alarm. 2. Fan/ motor bearing temperature≥800C: emergency priority alarm. 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm. 4. Fan bearing vibration≥11mm/sec: emergency priority alarm. 5. Motor winding temperature≥1100C: high priority alarm. 6. Motor winding temperature≥1200C: emergency priority alarm. TRIP 1. Motor winding temperature≥1300C (2 out of 6 temperatures with 60sec time delay). 2. Fan/ motor bearing temperature≥900C with 60 sec
PA Fan interlock & protection
1. No PA fan A/B converter/ device fault. 2. No PA fan protection acted. 3. PA fan A/B outlet damper closed. AND 4. PA fan IGV in minimum position. 5. APH A/B flue gas inlet & outlet damper open. 6. APH A/B running. 7. ID fan A/B running. 8. FD fan A/B running. 9. No boiler trip command. 1. PA fan A/B breaker protection acted. Or 2. MFT trip PA fan A/B. Or • 3. ID fan A/B tripped. Or 4. FD A/B tripped. Or 5. PA fan A/B temperature protection acted.
OR
Interl ock
Trip enabl e Interl ock:
ALARM 1. Fan/ motor bearing temperature≥75 0C: high priority alarm. 2. Fan/ motor bearing temperature≥80 0C: emergency priority alarm. 3. Fan bearing vibration≥6.3 mm/sec: high priority alarm. 4. Fan bearing vibration≥11mm/sec: emergency priority alarm. 5. Motor winding temperature≥110 0C: high priority alarm. 6. Motor winding temperature≥120 0C: emergency priority alarm.
TRIP 1. Motor winding temperature≥130 0C (2 out of 6 temperatures with 60 sec time delay). 2. Fan/ motor bearing temperature≥90 0C with 60 sec time delay. 3. Fan bearing vibration≥11mm/sec with 60 sec time delay. 4. PA fan motor protection (over current, earth fault, negative sequence, phase fault etc) acted. 5. MFT trip PA fan. 6. ID fan/ FD fan A/B trip to PA fan A/B trip. 7. PA fan running and fan discharge damper closed.
Seal air fan interlock & protection
1. No fan converter/ device/ breaker fault. 2. Any one PA fan running. 3. Fan IGV in minimum position. 4. In case of one fan running & other fan standbya) If running fan getting tripped due to any protection acting then stand by fan will start in interlock if selected. b) If seal air pressure becomes low (<6 KPa), then standby fan will start by interlock. 4. During unit start up fan start enable will come with the start of any PA fan if selected in fan auto start interlock. **Command will go to Seal air fan IGV for 60% opening in auto with
e interl ock:
• AND
• OR
1. Seal air fan current>200 Amp: high priority alarm. 2. Seal air fan current>260 Amp: emergency priority alarm. 3. Seal air discharge pressure<800: high priority alarm. 4. Seal air discharge pressure<600: emergency priority alarm. 1. Seal air fan current≥ 284Amp. 2. Both PA fans stopped/ tripped (fan trip after 2Sec).
ALARM
TRIP
Scanner Air Fan Interlock Protection
1. No motor or breaker protection acted. 2. Fan is in remote. 3. In case of one fan is running and the other is in stopped conditiona) By interlock input if one fan is stopped/ tripped, standby fan will start in auto. b) If scanner air header pressure<2 KPa for 5 sec, then standby fan will start in auto by interlock input. 1. Scanner air header pressure< low switch acting: emergency
AND
Start Enable Interlo ck
Alarm
Trip
Mill Interlock & Protection
1. No breaker/ motor protection acted. 2. Lube oil pressure normal for > 5 minutes. 3. No MFT acted. AND 4. Boiler drum pressure>3.4 kg/cm2. 5. Secondary air temperature>1770C. 6. Total air flow<40% (230TPH). 7. MDVs are open. 8. Mill outlet temperature<1150C.
Start Enable Interlock
1. Feeder trip and no mill ignition permit. 2. MFT. 3. MDVs closed. 4. Lube oil pressure low (2 out of 3 lube oil pressure
AND
1. Mill lube/ hydraulic oil tank temperature>750C: high priority alarm. 2. Mill lube oil thrust pad oil temperature>600C: high priority alarm. 3. Mill lube oil thrust pad oil temperature>700C: emergency priority alarm. 4. Mill motor front/ rear bearing temperature>750C: high priority alarm. 4. Mill motor winding temperature>1000C: high priority alarm. 5. Mill outlet, roller bearing temperature>900C: high priority alarm. 6. Mill current>60 amp: high priority alarm. 7. Mill inlet PA flow< 50 TPH: high
Alarm
1. Mill motor protection (over current, earth fault, negative sequence, phase fault etc) acted. 2. MFT trip mills. 3. MDVs closed trip mill (2 out of 4 MDVs). 4. Mill lube oil pressure low (2 out of lube oil pressure
Trip
Coal Feeder Interlock & Protection
Start enable Interlock: 1. No breaker or motor protection acted. 2. Respective mill ignition permit. 3. Feeder speed (VFD command) minimum. 4. No mill trip command. 5. Feeder is in remote.
Start Enable
AN D
1. 2. 3. 4.
Mill trip/ emergency stop. MFT. Feeder running and no coal. Mill outlet
OR
Interlo ck
Stop/Trip Enable Interlo ck:
1. Belt deviation of feeder switch act: high priority alarm. 2. No coal switch act: high priority alarm. 3. Coal jam switch act: low priority alarm. 4. Feeder cleaner motor fault: low priority alarm. 5. Coal flow zero: low priority alarm.
Alar m
Trip
1. Mill trip to feeder trip. 2. MFT to feeder trip. 3. Feeder motor/ breaker protection acted.
Mill Lub Oil Pump Interlock & Protection
1. No breaker or motor protection acted. 2. LOP is in remote. 3. Oil pool temperature of lube oil>600C.
1. Oil pool temperature of lube oil<450C. 2. After LOP starting if oil pool temperature of lube oil<450C and mill not running (30 mins time delay). 3. After mill stopping after 4 hrs time delay stop command will go for LOP.
Start enable Interlo ck
AND
OR
Stop/tri p enable Interlo ck
1. Lube oil pump stopped: emergency priority alarm. 2. Lube oil pressure
Ala rm
Trip
APH Interlock & Protection
• • • • •
1. No breaker or motor protection acted. 2. APH is in remote. 3. Guide and bearing oil pump running for minimum of 300 sec (for U#2 APH).
AND
Interl ock
Stop/tr ip enabl e Interl ock:
1. APH flue gas inlet temperature<800C OR and fans (ID, FD & PA) are running. 2. For APH auxiliary motor, with the start of APH main motor trip command will Other Interlocks: go. 1. Start command will go for APH auxiliary motor (DC) with the tripping of APH main motor. 2. In case of APH main motor VFD getting byed due to any fault, APH main motor DOL supply will pick up. 3. For U#2 APHa) If APH /guide bearing temperature> 54 0C, lube oil pump will start.
a h T s nk
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