bhel instrumentation

DIVISION – D CONTROL AND INSTRUMENTATION

VOLUME-D1

INSTRUMENTATION SCHEMES & SCHEDULES, SCHEDULE OF DAMPERS,LIST OF LT & SERVOMOTORS, DRUM LEVEL INSTRUMENTATION AND TAPPING POINT DETAILS, FSSS, SADC, SBC, EWLI, POWER CYLINDERS, LOCAL INSTRUMENT DETAIL LIST OF CONTENTS

Location Description Ref. No./ Drg.No

4006 – 4007 BATHINDA VOLUME-D1 of 3

TAB-1 INSTRUMENTATION SCHEMES & SCHEDULES, SCHEDULE OF DAMPERS, (1-80) LIST OF LT & SERVOMOTORS, DRUM LEVEL INSTRUMENTATION AND TAPPING POINT DETAILS Scheme of Air and Flue Gas Path with Instrumentation 0-97-288-90553 Scheme of Pulveriser System with Instrumentation 1-97-291-90237 Location of Thermocouples for SH & RH Metal temp. 0-97-293-90554 Measurement and Control Recommendation of Pulveriser 4-97-288-91647 System Measurement and Control Recommendation of Fuel Oil System 4-97-288-91645 Measurement and Control Recommendation of Water and Steam 4-97-288-91644 Recommended Write – up on Boiler Auto Controls Systems M/s. BHEL Measurement and Control Recommendation of Air & Flue Gas 1-97-291-91646 System Recommended Write – up on Interlocks and Protection for Boiler M/s. BHEL House Auxiliaries Recommended Write – up on Boiler Auto Controls Systems 4-97-096-91704 To 4-97-096-91719 Schedule of Dampers 4-97-599-91584 Schedule of LT Motors 4-97-599-91538 Schedule of Servomotors 4-97-599-91539 Drum Dished End Inst Tapping Details 4-97-287-91762 Physical Location of Tapping Points in Furnace Region 1-97-288-90247 Tappings Point Details Drawings 4-97-288-91545 To 4-97-288-91554

DIVISION – DCONTROL AND INSTRUMENTATION

VOLUME-D1

INSTRUMENTATION SCHEMES & SCHEDULES, SCHEDULE OF DAMPERS,LIST OFLT & SERVOMOTORS, DRUM LEVEL INSTRUMENTATION AND TAPPING POINT DETAILS, FSSS, SADC, SBC, EWLI, POWER CYLINDERS, LOCAL INSTRUMENT DETAIL LIST OF CONTENTS



TAB-2 FURNACE SAEGU ARD SUPERVISORY SUSTEM (FSSS) (81-196)

Write – up on FSSS M/s. BHEL

Basic Scope Diagram for FSSS 3-95-094-16217

List of Logic Drawings 3-95-094-16741 To 3-95-094-17013

FSSS Local Oil Gun Maintenance Switch Box 1-95-089-05320

Electrical Junction Box (with Brass Terminals) 1-95-091-10793

TAB-3 SECONDRY AIR DAMPER CONTROL SYSTEM (SADC)(197-216)

Basic Scope Diagram for SADC 3-95-194-16219

SADC- System – List of Drawings 3-95-194-16845 To 3-95-194-16852

Write – up on SADC M/s. BHEL

TAB-4 SOOT BLOWER CONTROLS (217-246)

Write – up on Soot Blower Control System M/s. BHEL

Soot Blower MCC – List of Drawings 3-96-186-09596 To 3-96-186-09605

Interconnection Diagram for Soot Blower System 3-96-186-10502 To 3-96-186-10515

DIVISION – DCONTROL AND INSTRUMENTATION

VOLUME-D1

INSTRUMENTATION SCHEMES & SCHEDULES, SCHEDULE OF DAMPERS,LIST OFLT & SERVOMOTORS, DRUM LEVEL INSTRUMENTATION AND TAPPING POINT DETAILS, FSSS, SADC, SBC, EWLI, POWER CYLINDERS, LOCAL INSTRUMENT DETAIL LIST OF CONTENTS



TAB-5 ELECTRONIC WATER LEVELINDICATOR (EWLI) (247-300)

Installation & Maintenance Manual (Version - II) M/s. BHEL

Installation / Part Drawings 3-97-088-14787 To 3-97-088-14457

TAB-6 POWER CYLINDERS (301-319)

Data Sheet for Preumatic Actuator M/s. BHEL

Terminal Block Wiring Diagram for Power Cylinder 4-97-599-11188

Instruction Manual for Power Cylinders M/s. Instrumentation Limited

TAB- 7 LOCAL INSTRUMENT DETAILS (320-331)

Pulv. Lube Oil System Interconnection – List of Drawings 3-95-289-17066 To 3-95-289-17077

TAB - 1

2091445B

4006 & 4007 VOL D1 TAB-1-1

2091445B

4006 & 4007 VOL D1 TAB-1-2

2091445B

4006 & 4007 VOL D1 TAB-1-3

2091445B

4006 & 4007 VOL D1 TAB-1-4

PROJECT : GTPS BATHINDA (R & M)CAPACITY : 2X120 MWUNITS # 3 & 4CUSTOMER: PUNJAB STATE ELECTRICITY BOARD CUST NO : 4006 4007

MEASUREMENT AND CONTROL RECOMMENDATIONS FOR PULVERISER SYSTEM BCR : 082

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

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01 HFE60 CP 401 PP PR. AT HOT PA HDR HOT PY. AIR 1 1850 x 1850

768 800 mmWC 228 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- - 00 --

02 HFE60 CP 001-003

PT PR. AT HOT PA HDR HOT PY. AIR 3 1850 x 1850

768 800 mmWC 228 270 OC -- -- -- -- -- D/ A,N,C -- mmWC

-- mmWC -- -- -- 4-97-288-91550 -- -- E 00 --

03 HFE60 CP101-103 PSLL PR. AT HOT PA HDR HOT PY. AIR 3

1850 x 1850 768 800 mmWC 228 270 OC -- -- -- -- -- F/ N 500

260 to 1100

mmWC -- -- COD SOR INC

12RN-EE614-M4-C2A-TTYYVV-PKA7X

4-97-288-91550 1/2" NPT-F3/4" NPT-

F T 01 Immediate Trip

04 HFE60 CP104-105 PSAL PR. AT HOT PA HDR HOT PY. AIR 2

1850 x 1850 768 800 mmWC 228 270 OC -- -- -- -- -- F/ A, N 520

100 to 1000

mmWC -- -- COD

SWITZERINSTRUMEN

T LTD

GM 201-02-C4K-

55-Z4-97-288-91550 1/2" NPT-F

3/4" NPT-F T 01

05 HFE61-64 CP 401 PP PR. AT HOT PA SHUT OFF GATE

HOT PY. AIR 4 1300 x 1300

768 800 mmWC 228 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- - 00 --

06 HFE61-64 CP 402 PP PR. AFTER HOT PA SHUT OFF GATE

HOT PY. AIR 4 1300 x 1300

768 800 mmWC 228 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- - 00 --

07 HFE61-64 CT 401 TP TEMP AFTER HOT PA REG. DAMPER

HOT PY. AIR 4 1300 x 1300

693 725 mmWC 228 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- 4-97-288-91551 -- -- - 00 --

08 HFE61-64 CP 403 PP PR. AFTR HOT PA REG. DMPR HOT PY. AIR 4 1300 x 1300

693 725 mmWC 228 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- - 00 --

09 HFE50 CP 401 PP PR. AT COLD PA HDR COLD PY. AIR 1 900 x900

900 943 mmWC 35 55 OC T -- -- -- -- -- -- 4-97-288-91550 -- - 00 --

10 HFE51-54 CP 402 PP PR. AFTR COLD PA GATE COLD PY. AIR 4 650 x650

693 725 mmWC 35 55 OC -- -- -- -- T -- -- -- -- mmWC -- -- -- 4-97-288-91550 -- -- - 00 --

11 HFE51-54 CP 403 PP PR. AFTR COLD PA REG. DAMPER

COLD PY. AIR 4 650 x650

693 725 mmWC 35 55 OC -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- - 00 --

12 HFE61-64 CT 001-003

TE TEMP. - MXD AIR BFR MILL:A-E HOT & COLD PY. AIR

12 1300 x 1300

668 696 mmWC 184 270 OC -- -- -- -- -- D/ I,C -- -- OC -- OC -- -- -- 4-97-288-91551 -- -- E 00 --

13 HFE61-64 CF 001-003

FT FLOW - MXD AIR BFR MILL:A-E HOT & COLD PY. AIR

12 1300 x 1300

668 696 mmWC 184 270 OC -- 77.00 t/h -- -- D/ I,C -- -- mmWC

-- t/h -- -- -- -- -- E 00 FE by BHEL Trichy

14 HFE61-64 CP 001 PT PR.- MXD AIR BFR MILL:A-E HOT & COLD PY. AIR

4 1300 x 1300

668 696 mmWC 184 270 OC -- -- -- -- -- D / I -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- E 00 --

15 HFE61-64 CP 404 PP PR.- MXD AIR BFR MILL:A-E HOT & COLD PY. AIR

4 1300 x 1300

668 696 mmWC 184 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91550 -- -- - 00 --

16 HFE61-64 CT 402 TP TEMP. - MXD AIR BFR MILL:A-E HOT & COLD PY. AIR

4 1300 x 1300

668 696 mmWC 184 270 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- 4-97-288-91551 -- -- - 00 --

18 HFC01-04 CT 501 TI TEMP. AT MILL MTR:A-D NDE BRG

METAL 4 -- -- -- -- T -- OC -- -- -- -- -- I -- -- OC -- -- -- -- -- --- -- -- H 00 T=ACTUAL RUNNING TEMP. OBSERVED

19 HFC01-04 CT 001 TE TEMP. AT MILL MTR:A-D NDE BRG

METAL 4 -- -- -- -- T -- OC -- -- -- -- -- D/I,A,N T+5/T+10 -- OC -- OC -- -- -- --- -- -- H 00 --

DRG NO.:4-97-288-91647/01SHEET 2 OF 3

2091445B

4006 & 4007 VOL D1 TAB-1-5


MEASUREMENT AND CONTROL RECOMMENDATIONS FOR PULVERISER SYSTEM BCR : 082

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

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20 HFC01-04 CT 002-013

TE TEMP. AT MILL MTR:A-D WNDG METAL 48 -- -- -- -- T -- OC -- -- -- -- -- D/I,A,N T+5/T+10 -- OC -- OC -- -- -- --- -- -- H 00 --

21 HFC01-04 CT 014 TE TEMP. AT MILL MTR:A-D DE BRG

METAL 4 -- -- -- -- T -- OC -- -- -- -- -- D/I,A,N T+5/T+10 -- OC -- OC -- -- -- --- -- -- H 00 --

22 HFC01-04 CT 502 TI TEMP. AT MILL MTR:A-D DE BRG

METAL 4 -- -- -- -- T -- OC -- -- -- -- -- I -- -- OC -- -- -- -- -- --- -- -- H 00 --

24 HFC01-04 CT 503 TI TEMP. AT MILL :A-D OIL BATH LUBE OIL 4 -- -- -- -- T -- OC -- -- -- -- -- I -- -- OC -- -- -- -- -- --- -- -- H 00 --

25 HFC01-04 CT015-017 TE TEMP. AT MILL:A-D O/L AIR + COAL 12 -- 307 384 mmWC

66-90 90 OC -- -- -- -- -- D/I,C,N -- OC -- OC -- -- -- 4-97-288-91551 -- -- E 00

CONTACT IS REQD FROM STN CI FOR FSSS

26 HFC01-04 CP 101 PDSH DP ACROSS MILL BOWL AIR + COAL 4 -- 307 384 mmWC 85 90 OCDP=200

-- mmWC -- -- F/N 300 50 to 1200

mmWC

-- -- COISWITZER

INSTRUMENT LTD

GM 301-02-EID-DD-Z

1/2" NPT-F 3/4" NPT-F

T 01 RUN FEEDER SPEEDTO MINIMUM

27 HFC01-04 CP 001 PDT DP ACROS MILL BOWL AIR + COAL 4 -- 307 384 mmWC 85 90 OCDP=200

-- mmWC -- -- F/N -- mmWC

-- mmWC -- -- -- -- -- E 00 RUN FEEDER SPEEDTO MINIMUM

28 HFC01-04 CP 401 PP DP ACROS MILL BOWL AIR + COAL 4 -- 307 384 mmWC 85 90 OC -- -- mmWC -- -- T -- -- -- -- -- -- -- -- - 00 --

29 HFC01-04 CT 018-022

TE TEMP. AT MILL:A-D REJECT COAL 20 -- -- -- -- T -- OC -- -- -- -- -- D/I,A -- OC -- OC -- -- -- 4-97-288-90486 -- -- E 00 --

30 HFW10 CP 101 PDAH PR.ACROSS DYNA FLTR SEAL AIR 1 -- -- -- mmWC -- -- OCDP=150 -- mmWC -- -- D / A N 170

50 to 1200

mmWC -- -- COI

SWITZERINSTRUMEN

T LTD

GM 301-02-EID-DD-Z

--- 1/2" NPT-F3/4" NPT-

F T 01 --

31 HFW10 CP 501 PDC PR. AFTR DYNA FLTR O/L SEAL AIR 1 -- 754 -- mmWC 45 -- OC -- -- -- -- -- LC -- -- S -- -- -- -- -- --- -- -- T 00LOCAL PNEUMATIC CONTROLLER BY FS/PE(B)

32 HFW10 CP 401 PP PR. AFTR DYNA FLTR O/L SEAL AIR 1 -- 754 -- mmWC 45 -- OC -- -- -- -- -- T -- -- -- -- -- -- -- -- --- -- -- - 00 --

33 HFW20 CP101-102 PDSL

DP ACROS SEAL AIR HDR/COLD PA HDR

SEAL AIR / COLD PA HDR 2 -- -- -- mmWC -- -- OC

DP=400 -- mmWC -- -- F/ N 100

50 to 1200

mmWC -- mmWC COD

SWITZERINSTRUMEN

T LTD

GM 301-02-EID-DD-Z

1/2" NPT-F3/4" NPT-

F T 01changeover to the other seal air fan

34 HFW20 CP 501 PI PR. AT SEAL AIR DIS. SEAL AIR 1 NB 650 1260 -- mmWC 45 50 OC -- -- -- -- -- L/I -- 0-2000

mmWC

-- -- -- MONOMETER(I)P.LTD

-- --- --- -- T 01 --

35 HFW20 CT 401 TP TEMP. AT SEAL AIR DIS. SEAL AIR 1 NB 650 1260 -- mmWC 45 50 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- --- -- -- - 00 --

36 HFW20 CP 401 PP PR. AT SEAL AIR DIS. SEAL AIR 1 NB 650 1260 -- mmWC 45 50 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- --- -- -- - 00 --

37 HFW20 CP 001 PT PR. AT SEAL AIR DIS. SEAL AIR 1 NB 650 1260 -- mmWC 45 50 OC -- -- -- -- -- D/ I -- -- mmWC

-- mmWC -- -- -- 4-97-288-91550 -- -- E 00 --

38 HFW21-24 CP 401 PP PR. AT SEAL AIR TO MILL :A-E DMPR

SEAL AIR 4 NB 250 1260 -- mmWC 45 50 OC -- -- -- -- -- T -- -- -- -- -- -- -- -- --- -- -- - 00 --

39 HFW21-24 CP 101 PDSL DP ACROSS SEALAIR HDR / MILL:A-E UNDR BWL

SEAL AIR 4 -- -- -- mmWC -- -- OCDP=250

-- mmWC -- -- F/ N 125* 50 to 1200

mmWC

-- mmWC CODSWITZER

INSTRUMENT LTD

GM 301-02-EID-DD-Z

1/2" NPT-F 3/4" NPT-F

T 01 * Mill to Trip with the delay of 1 Min.

40 HFW21-24 CP 102 PDSHDP ACROSS SEALAIR HDR /MILL:A-E UNDR BWL SEAL AIR 4 -- -- -- mmWC -- -- OC

DP=250 -- mmWC -- -- F/A,N 200^

50 to 1200

mmWC -- mmWC COI

SWITZERINSTRUMEN

T LTD

GM 301-02-EID-DD-Z

1/2" NPT-F3/4" NPT-

F T 01^ For Mill Startup Permissive

DRG NO.:4-97-288-91647/01SHEET 3 OF 3

2091445B

4006 & 4007 VOL D1 TAB-1-6

2091445B

4006 & 4007 VOL D1 TAB-1-7

PROJECT : GTPS BATHINDA (R M)CAPACITY : 2X120 MWUNITS # 3 4CUSTOMER: PUNJAB STATE ELECTRICITY BOARD CUST NO : 4006 4007

Measurement and Control Recommendation of Fuel Oil system BCR : 582

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

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1 HJF60 CT 101 TSCH TEMP-OP FLR HFO HFO 1 NB 50 19.5 Kg/cm2 ft oC F/N ft 90-200 Deg.c COD

SWITZERINSTRUMENT

LTD

GM731-OT-Q4K-

55-ZM33X2(F) M33X2(M) 3/4"NPT(F) T 01 TEMP OK

2 HJF60 CT 501 TI TEMP-OP FLR HFO HFO 1 NB 50 19.5 Kg/cm2 ft oC L/ I 0-200 Deg.c

WAAREEINSTRUMENTS

LTDM33X2(F) M33X2(M) -- T 01

3 HJF60 CP 501 PI PR-OP.FLR HFO HFO 1 NB 50 19.5 Kg/cm2 ft oC L/ I 0-60 Kg/sq.cm

WAAREEINSTRUMENTS

LTDM20X1.5(F) M20X1.5(M) -- T 01

4 HJF61 CP 101 PDSAH DP ACROS OP FLR STNR HFO 1 NB 50 DP=0.1 D/ A 0.3 0.1-

1.5Kg/sq.cm COI

SWITZERINSTRUMENT

LTD

GM301-02-G5B-

DD-Z25 mm SW 1/2" NPT(F) 3/4"NPT(F) T 01

5 HJF62 CP 101 PDSAH DP ACROS OP FLR STNR HFO 1 NB 50 DP=0.1 D/ A 0.3 0.1-

1.5Kg/sq.cm COI

SWITZERINSTRUMENT

LTD

GM301-02-G5B-

DD-Z25 mm SW 1/2" NPT(F) 3/4"NPT(F) T 01

6 HJF63 CP 501 PI PR. AFTER OP FLR STRAINER HFO 1 NB 50 19 Kg/cm2 ft oC -- -- -- -- -- L/ I 0-60 Kg/sq

.cm

WAAREEINSTRUMENTS

LTDM20X1.5(F) M20X1.5(M) -- T 01

7 HJF63 CP 101 PSCH PR. OP FLR HFO HFO 1 NB 50 19 Kg/cm2 ft oC F/N 18 8 to 32

Kg/sq.cm COI

SWITZERINSTRUMENT

LTD

GM201-02-C4K-

55-Z25 mm SW 1/2" NPT(F) 3/4"NPT(F) T 01 PR. OK

8 HJF63 CF 001 FM FLOW - OP.FLR HFO HFO 1 NB 50 19 Kg/cm2 ft oC8.6 to

1.2 -- T/Hr -- -- D/I --Kg/cm2

Kg/cm2 -- -- -- -- T 00 MASS FLOW

METER

9 HJF63 CP 502 PI PR. AFTER OP FLR STRAINER HFO 1 NB 50 19 Kg/cm2 ft oC -- -- -- -- -- L/ I 0-60 Kg/sq

.cm

WAAREEINSTRUMENTS

LTDM20X1.5(F) M33X2(M) -- T 01

10 HJF63 CP 401 PP PR. AT HFO HEADER HFO 1 NB 50 13 to 4.5 Kg/cm2 ft -- oC -- -- -- -- -- T -- -- -- -- 25 mm SW --- -- 00 --

11 HJF63 CP 503 PI PR. AT HFO HEADER HFO 1 NB 50 13 to 4.5 Kg/cm2 ft -- oC -- -- -- -- -- L/ I -- 0 to 25

Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) M20X1.5(M) -- T 01

12 HJF63 CP 001-002 PT PR. AFTR HOFCV HFO 2 NB 50 13 to 4.5 Kg/cm2 ft -- oC -- -- -- -- -- D/I,CKg/cm2

Kg/cm2 -- -- -- -- E 00

13 HJF63 CP 102 - 104 PSCL PR. AT HFO HEADER HFO 3 NB 50 13 to 4.5 Kg/cm2 ft -- oC F/ N 3.5 1.6to16

Kg/sq.cm COD

SWITZERINSTRUMENT

LTD

GM201-02-A8K-

55-Z25 mm SW 1/2" NPT(F) 3/4"NPT(F) T 01 LOW TRIP

14 HJF63 CP 105 PSAL PR. AT HFO HEADER HFO 1 NB 50 13 to 4.5 Kg/cm2 ft -- oC D/ A 4 1.6to16

Kg/sq.cm COD

SWITZERINSTRUMENT

LTD

GM201-02-A8K-

55-Z25 mm SW 1/2" NPT(F) 3/4"NPT(F) T 01 LOW ALARM

15 HJF63 CT 001 TE TEMP. AT HFO HDR HFO 1 NB 50 13 to 4.5 Kg/cm2 ft -- oC -- -- -- D/ I 0C 0C -- M33X2(F) -- -- E 00

16 HJF63 CT 501 TI TEMP. AT HFO HEADER HFO 1 NB 50 13 to 4.5 Kg/cm2 ft -- oC -- -- -- -- -- L/ I -- 0-200 Deg.c -- --

WAAREEINSTRUMENTS

LTDM33X2(F) M33X2(M) -- T 01 --

17 HJF63 CT 104 TSAL TEMP. AT HFO HDR HFO 1 NB 50 13 to 4.5 Kg/cm2 ft -- oC D/ A ft-5 90-200 Deg.c COD

SWITZERINSTRUMENT

LTD

GM731-OT-Q4K-

55-ZM33X2(F) M33X2(M) 3/4"NPT(F) T 01 LOW ALARM

Drg. No:4-97-288-91645 / 01Page 2 of 4

2091445B

4006 & 4007 VOL D1 TAB-1-8



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18 HJF63 CT 101 -103 TSCL TEMP. AT HFO HDR HFO 3 NB 50 13 to 4.5 Kg/cm2 ft -- oC F/ N ft-15 90-200 Deg.c COD

SWITZERINSTRUMENT

LTD

GM731-OT-Q4K-

55-ZM33X2(F) M33X2(M) 3/4"NPT(F) T 01 LOW TRIP

19 HJF67 CT 501 TI TEMP. AT RTN LINE HFO 1 NB 40 1.0 - 2.0 Kg/cm2 ft -- oC -- -- -- -- -- L/ I -- 0-200 Deg.c -- --

WAAREEINSTRUMENTS

LTDM33X2(F) M33X2(M) -- T 01 --

20 HJF67 CP 501 PI PR. AT RTN LINE HFO 1 NB 40 1.0 - 2.0 Kg/cm2 ft -- oC -- -- -- -- -- L/ I 0-60 Kg/sq.cm --

WAAREEINSTRUMENTS

LTDM20X1.5(F) M20X1.5(M) -- T 01

21 HJM40 CP 501 PI PR. BFR ASPRV STEAM 1 NB 50 11 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-25 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) M20X1.5(M) -- T 01

22 HJM40 CT 501 TI TEMP. AT AS HDR STEAM 1 NB 50 11 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-400 Deg.c -- --

WAAREEINSTRUMENTS

LTDM33X2(F) M33X2(M) -- T 01 --

23 HJM40 CP 502 PI PR. BFR ASPRV STEAM 1 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-16 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) -- T 01

24 HJM40 CP 001-002 PT PR. AT AUX ST HDR STEAM 2 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- D/I,C,AKg/cm2

Kg/cm2 -- -- -- -- E 00 LOW ALARM, LOW

TRIP

25 HJM40 CP 101 PSAL PR. AT AUX ST HDR STEAM 1 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- D/A 4 1 to 10

Kg/sq.cm -- COD

SWITZERINSTRUMENT

LTD

GM201-02-A7K-


26 HJM40 CP 102-103 PSCL PR. AT AUX ST HDR STEAM 2 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- F/N 3.5 1 to 10

Kg/sq.cm -- COD

SWITZERINSTRUMENT

LTD

GM201-02-A7K-


27 HJM40 CT 101 TE TEMP. AT AUX ST HDR STEAM 1 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- D/I -- -- M33X2(F) -- -- E 01

28 HJM40 CP 401 PP PR. AT AUX ST HDR STEAM 1 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- T -- 0-16 -- -- 15 mm SW -- -- -- 00 --

29 HJM40 CT 502 TI TEMP. AT AS HDR STEAM 1 NB 50 7.5 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-400 Deg.c -- --

WAAREEINSTRUMENTS

LTDM33X2(F) M33X2(M) -- T 01 --

30 HJF30 CP 501 PI PR. BEFORE LOTV LDO 1 NB40 16 Kg/cm2 35 oC L/I 0-40 Kg/sq.cm COI

WAAREEINSTRUMENTS M20X1.5(F) M20X1.5(M) -- T 01 PR. OK

31 HJF30 CP 101 PSCH PR. BEFORE LOTV LDO 1 NB40 16 Kg/cm2 35 oC F/N 14 8 to 32

Kg/sq.cm COI

SWITZERINSTRUMENT

LTD

GM201-02-C4K-

55-Z15 mm SW 1/2" NPT(F) 3/4"NPT(F) T 01 PR. OK

32 HJF30 CF 001 FT FLOW - OP.FLR LFO LDO 1 NB40 16 Kg/cm2 35 oC4.3 TO

1.2 -- T/Hr -- -- D/ I --Kg/cm2

Kg/cm2 -- -- -- -- T 00 MASS FLOW

METER

33 HJF30 CP 502 PI PR. BEFORE LOFCV LDO 1 NB40 16 Kg/cm2 35 -- oC -- -- -- -- -- L/I 3,3.5 0-40 Kg/sq.cm

Kg/cm2 --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) -- T 01

34 HJF30 CP 503 PI PR. AT LDO HDR LDO 1 NB40 11-3.5 Kg/cm2 35 -- oC -- -- -- -- -- L/ I -- 0-25 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) -- T 01

35 HJF30 CP 401 PP PR. AT LDO HDR LDO 1 NB40 11-3.5 Kg/cm2 35 -- oC -- -- -- -- -- T 0-25 -- COD 15 mm SW -- -- -- 00

36 HJF30 CP 001-002 PT PR. AT LDO HDR LDO 2 NB40 11-3.5 Kg/cm2 35 -- oC -- -- -- -- -- DC/I 0-25 -- COD -- -- -- E 00

37 HJF30 CP 102 PSAL PR. AT LDO HDR LDO 1 NB40 11-3.5 Kg/cm2 35 -- oC -- -- -- -- -- D/A 2.5 -- -- -- 15 mm SW 1/2" NPT(F) 3/4"NPT(F) -- 00 LOW ALARM

38 HJF30 CP 103-105 PSCL PR. AT LDO HDR LDO 3 NB40 11-3.5 Kg/cm2 35 -- oC -- -- -- -- -- F/N 2.1 1.6-16

Kg/sq.cm -- COD

SWITZERINSTRUMENT

LTD

GM201-02-A8K-


39 HJN10 CP 501 PI PR. AT AA HDR ATOM. AIR 1 NB 50 5.6 to 7 -- Kg/cm2 35 -- oC -- -- -- -- -- L/ I -- 0-16 Kg/sq.cm

Kg/cm2 --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) -- T 01

Drg. No:4-97-288-91645 / 01Page 3 of 4

2091445B

4006 & 4007 VOL D1 TAB-1-9



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40 HJN10 CP 001 PT PR. AT AA HDR ATOM. AIR 1 NB 50 5.6 to 7 Kg/cm2 35 -- oC -- -- -- -- -- D/I -- -- -- -- -- -- -- E 00 --

41 HJN10 CP 401 PP PR. AT AA HDR ATOM. AIR 1 NB 50 5.6 to 7 -- Kg/cm2 35 -- oC -- -- -- -- -- T --Kg/cm2

Kg/cm2 COD 15 mm SW -- -- -- 00

42 HJN10 CP 101-102 PSCL PR. AT AA HDR ATOM. AIR 1 NB 50 5.6 to 7 -- Kg/cm2 35 -- oC -- -- -- -- -- F/N 3 1 to 10

Kg/sq.cm

Kg/cm2 COD

SWITZERINSTRUMENT

LTD

GM201-02-A7K-


43 HJN10 CP 103 PSAL PR. AT AA HDR ATOM. AIR 1 NB 50 5.6 to 7 -- Kg/cm2 35 -- oC -- -- -- -- -- F/N 3.5 1 to 10

Kg/sq.cm -- COI

SWITZERINSTRUMENT

LTD

GM201-02-A7K-


44 HJF11,12,13&14 CP 301 PI PR.AT.BNR FRONT EL-

AB HFO / LDO 4 NB 25 11/10 -- Kg/cm2 ft / 35 -- oC -- -- -- -- -- L/ I -- 0-25 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTD'M20X1.5(M) T 01


ABSTEAM /

AIR 4 NB 25 6/6 -- Kg/cm2 210 / 35 -- oC -- -- -- -- -- L/ I -- 0-10 Kg/sq

.cm -- --WAAREE

INSTRUMENTSLTD

'M20X1.5(M) T 01


CD HFO 4 NB 25 11 -- Kg/cm2 ft -- oC -- -- -- -- -- L/ I -- 0-25 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) -- T 01


CD STEAM 4 NB 25 6.00 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-10 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) T 01

48 HJF50 CT 501 TI TEMP. BEFORE HEATER SET HFO 1 NB 50 22.00 -- Kg/cm2 pt -- oC -- -- -- -- -- L/ I -- 0-

100 Deg.c -- --WAAREE

INSTRUMENTSLTD

M33X2(F) M33X2(M) T 01

49 HJF50 CT 401 TW TEMP. BEFORE HEATER SET HFO 1 NB 50 22.00 -- Kg/cm2 pt -- oC -- -- -- -- -- T -- -- -- M20X1.5(F) -- 00

50 HJF50 CT 101 TE TEMP. BEFORE HEATER SET HFO 1 NB 50 22.00 -- Kg/cm2 pt -- oC -- -- -- -- -- D/I -- -- -- M33X2(F) E 01

51 HJF60 CT 101 TSAL TEMP. AFTR HEATER SET HFO 1 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- D/ A -- 90-

200 Deg.c -- CODSWITZER

INSTRUMENTLTD

GM731-OT-Q4K-

55-ZM33X2(F) M33X2(M) 3/4"NPT(F) T 01 LOW ALARM

52 HJF60 CT 401 TW TEMP. AFTR HEATER SET HFO 1 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- T -- -- -- M20X1.5(F) -- 00

53 HJF60 CT 501 TI TEMP. AFTR HEATER SET HFO 1 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- L/ I -- 0-

200 Deg.c -- --WAAREE

INSTRUMENTSLTD

M33X2(F) M33X2(M) T 01

54 HJF60 CT 001&002 TE TEMP. AFTR HEATER SET HFO 2 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- D/ I -- -- -- M33X2(F) --- E 00

55 HJF60 CP 001&002 PT PR. AFTR HEATER SET HFO 2 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- D/I,C -- -- -- E 00

56 HJF60 CP 501 PI PR. AFTR HEATER SET HFO 1 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- L/ I -- 0-60 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) -- T 01

57 HJF60 CP 401 PP PR. AFTR HEATER SET HFO 1 NB 50 21.00 -- Kg/cm2 ft+5 -- oC -- -- -- -- -- T -- -- -- 25 mm SW --- -- 00

58 HJF54 CP 501 PI PR. BEFORE HOPCV HFO 1 NB 40 1.5 TO 3.5 -- Kg/cm2 -- -- oC -- -- -- -- -- L/ I -- 0-10 Kg/sq

.cm -- --WAAREE

INSTRUMENTSLTD

M20X1.5(F) 'M20X1.5(M) -- T 01

59 HJF54 CP 502 PI PR. AFTR HOPCV HFO 1 NB 40 1.5 TO 3.5 -- Kg/cm2 -- -- oC -- -- -- -- -- L/ I -- 0-10 Kg/sq

.cm -- --WAAREE

INSTRUMENTSLTD

M20X1.5(F) 'M20X1.5(M) -- T 01

60 HJT50 CP 502 PI PR. BEFORE HOTCV STEAM 1 NB 50 11.00 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-25 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) T 01

61 HJT50 CP 501 PI PR. AFTR HOTCV STEAM 1 NB 50 11.00 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-25 Kg/sq.cm -- --

WAAREEINSTRUMENTS

LTDM20X1.5(F) 'M20X1.5(M) T 01

62 HJT50 CT 501 TI TEMP. AFTR HOTCV STEAM 1 NB 50 11.00 -- Kg/cm2 210 -- oC -- -- -- -- -- L/ I -- 0-400 Deg.c -- --

WAAREEINSTRUMENTS

LTDM33X2(F) M33X2(M) T 01

Drg. No:4-97-288-91645 / 01Page 4 of 4

2091445B

4006 & 4007 VOL D1 TAB-1-10

2091445B

4006 & 4007 VOL D1 TAB-1-11

PROJECT : GTPS BATHINDA (R & M)CAPACITY : 2X120 MWUNITS # 3 & 4CUSTOMER: PUNJAB STATE ELECTRICITY BOARD CUST NO : 4006 & 4007

Measurement and Control Recommendation of Water Steam systemBCR : 574

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

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1 HAC10 CP 001 PT PR. AT ECO. I/L WATER 1 D33.4X6.35 151.1 161.8 Kg/cm2 239 244 0 C -- -- -- -- -- D/I -- Kg/cm2 Kg/cm2 -- -- -- -- -- E 00

2 HAC10 CT 001 TE TEMP. AT ECO. I/L WATER 1 D273 X 28 151.1 161.8 Kg/cm2 239 244 0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

3 HAC10 CT 401 TW TEMP. AT ECO. I/L WATER 1 D273 X 28 151.1 161.8 Kg/cm2 239 244 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

4 HAC10 CP 401 PP PR. AT ECO. I/L WATER 1 D33.4X6.35 151.1 161.8 Kg/cm2 239 244 0 C -- -- -- -- -- T -- -- -- -- -- -- --- -- 00

5 HAC10 CP 501 PI PR. AT ECO. I/L WATER 1 D33.4X6.35 151.1 161.8 Kg/cm2 239 244 0 C -- -- -- -- -- L/ I -- 0-250 kg/sq.cm -- --

WAAREEINSTRUMENTS LTD

-- M20 X 1.5[M] T 01

6 HAC10 CT 501 TI TEMP. AT ECO. I/L WATER 1 D273 X 28 151.1 161.8 Kg/cm2 239 244 0 C -- -- -- -- -- L/ I -- 0-400 Deg.c -- --


-- 4-97-288-91148

M33 X 2 [M] T 01

7 HAC11 CT 401 TW TEMP. AT ECO. O/L - L WATER 1 D219.1x 22.3 148.2 161.3 Kg/cm2 297 299 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

8 HAC11 CT 001 TE TEMP. AT ECO. O/L - L WATER 1 D219.1x 22.3 148.2 161.3 Kg/cm2 297 299 0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

9 HAC12 CT 401 TW TEMP. AT ECO. O/L - R WATER 1 D219.1x 22.3 148.2 161.3 Kg/cm2 297 299 0 C -- -- -- -- -- T -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

10 HAC12 CT 001 TE TEMP. AT ECO. O/L - R WATER 1 D219.1x 22.3 148.2 161.3 Kg/cm2 297 299 0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

11 HAD10 CL 002 LT LEVEL AT DRUM - L WATER & STEAM 1 D48.3 X

7.14 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- D/I,N,A -- -- -- -- -- -- --- --- E 00

12 HAD10 CL 003 LT LEVEL AT DRUM - R WATER & STEAM 1 D48.3 X

7.14 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- D/I,N,A -- -- -- -- -- -- --- --- E 00

13 HAD10 CL 004 LT LEVEL AT DRUM - R WATER & STEAM 1 D48.3 X

7.14 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- D/I,N,A -- -- -- -- -- -- --- --- E 00

14 HAD10 CL 501 DWLG LEVEL AT DRUM - L WATER & STEAM 1 D48.3 X

7.14 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- L/ I -- -- -- -- -- -- --- --- T 01

15 HAD10 CL 001 EWLI LEVEL AT DRUM - L WATER & STEAM 1 D33.4X

6.35 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- D/ I,N -- -- -- -- BHELBHELVISION20

M--- --- T 01

16 HAD10 CL 502 DWLG LEVEL AT DRUM - R WATER & STEAM 1 D48.3 X

7.14 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- L/ I -- -- -- -- BHEL -- --- --- T 01

17 HAD10 CL 005 EWLI LEVEL AT DRUM - R WATER & STEAM 1 D33.4X

6.35 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- D/ I,N -- -- -- -- BHELBHELVISION20

M--- --- T 01

18 HAD10 CT 101-112 TE TEMP.(METAL) AT DRUM METAL 12 -- -- -- -- -- -- -- -- -- -- -- -- D/I -- 0 C 0 C -- BHEL -- 4-97-288-

91548M33 X 2 [M] T 01

19 HAD10 CP 001-002 PT PR. AT DRUM WATER &

STEAM 2 D33.4X6.35 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- D/I,C -- Kg/cm2 Kg/cm2 -- -- -- -- E 00

Drg. No:4-97-288-91644/01Page 2 of 4

2091445B

4006 & 4007 VOL D1 TAB-1-12



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20 HAD10 CP 501 PI PR. AT DRUM WATER & STEAM 1 D33.4X

6.35 148.2 158.2 Kg/cm2 340 346 0 C -- -- -- -- -- L/ I -- 0-250 kg/sq.cm -- --WAAREE

INSTRUMENTS LTD

-- -- M20 X 1.5[M] T 01

21 HAH10 CT 001 TE TEMP.AT LTSH HDR STEAM 1 D368 X 40 145.4 155.4 Kg/cm2 347 357 0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

22 HAH10 CT 002 TE TEMP.AT LTSH HDR STEAM 1 D368 X 40 145.4 155.4 Kg/cm2 347 357 0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

23 HAH10 CT 401 TW TEMP.AT LTSH HDR STEAM 1 D368 X 40 145.4 155.4 Kg/cm2 347 357 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

24 HAH10 CT 402 TW TEMP.AT LTSH HDR STEAM 1 D368 X 40 145.4 155.4 Kg/cm2 347 357 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

25 HAH10 CT 003-020 TE TEMP.(METAL) AT LTSH TUBE I/L METAL 18 -- -- -- -- -- -- -- -- -- -- -- -- D/I 539 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] T 01

26 HAH20 CT 001 TE TEMP. AT LTSH O/L STEAM 1 D 323.9 X 32 144.6 155 Kg/cm2 457 467 0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

27 HAH20 CT 401 TW TEMP. AT LTSH O/L STEAM 1 D 323.9 X 32 144.6 155 Kg/cm2 457 467 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

28 HAH50 CT 401 TW TEMP. AT LTSH O/L STEAM 1 D 323.9 X 32 144.6 155 Kg/cm2 457 467 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 01

29 HAH50 CT 001 TE TEMP. AT LTSH O/L STEAM 1 D 323.9 X 32 144.6 155 Kg/cm2 457 467 0 C -- -- -- -- -- D/I -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] E 01

30 HAH30 CT 001-003 TE TEMP. AT DESH O/L STEAM 3 D 323.9

X 32 142.9 152.9 Kg/cm2 446 456 0 C -- -- -- -- -- D/I/C -- 0 C 0 C -- -- -- 4-97-288-91548

M33 X 2 [M] E 00

31 HAH30 CT 401 TW TEMP. AT DESH O/L STEAM 1 D 323.9 X 32 142.9 152.9 Kg/cm2 446 456 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

32 HAH60 CT 001-003 TE TEMP. AT DESH O/L STEAM 3 D 323.9

X 32 142.9 152.9 Kg/cm2 446 456 0 C -- -- -- -- -- D/I,C -- -- -- -- -- -- 4-97-288-91549

M33 X 2 [M] E 01

33 HAH60 CT 401 TW TEMP. AT DESH O/L STEAM 1 D 323.9 X 32 142.9 152.9 Kg/cm2 446 456 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 01

34 HAH40 CT 001-029 TE TEMP. AT PLATEN SH HDR METAL 29 -- -- -- -- -- -- -- -- -- -- -- -- D/I 583 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00

35 LBA01 CP 501 PI PR.ATSH MAIN STEAM LINE-L STEAM 1 D33.4X6.35 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- L/ I -- 0-250 Kg/sq.cm -- --


-- -- M20 X 1.5[M] T 01

36 LBA01 CP 001-003 PT PR AT SH MAIN STEAM LINE -L STEAM 3 D33.4X

6.35 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- D/I,C -- Kg/cm2 0 C -- -- -- -- E 01

37 LBA01 CT 501 TI TEMP.AT SH MAIN STEAM LINE -L STEAM 1 D323.9X 31 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- L/ I -- 0-600 Deg.c -- --


-- 4-97-288-91148

M33 X 2 [M] T 01

38 LBA01 CT 001-003 TE TEMP.AT SH MAIN STEAM LINE -L STEAM 3 D323.9

X 31 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- D/I/C -- 0 C 0 C -- -- -- 4-97-288-91548

M33 X 2 [M] E 00

39 LBA01 CT 401 TW TEMP.AT SH MAIN STEAM LINE -L STEAM 1 D323.9X 31 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- T -- 0 C -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

40 LBA02 CP 501 PI PR.ATSH MAIN STEAM LINE-R STEAM 1 D33.4X6.35 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- L/ I -- 0-250 Kg/sq.cm -- --


-- -- M20 X 1.5[M] T 01

41 LBA02 CP 001-003 PT PR AT SH MAIN STEAM LINE -R STEAM 3 D33.4X

6.35 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- D/I,C -- Kg/cm2 0 C -- -- -- -- E 01

42 LBA02 CT 501 TI TEMP.AT SH MAIN STEAM LINE -R STEAM 1 D323.9X 31 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- L/ I -- 0-600 Deg.c -- --


-- 4-97-288-91148

M33 X 2 [M] T 01

43 LBA02 CT 001-003 TE TEMP.AT SH MAIN STEAM LINE -R STEAM 3 D323.9

X 31 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- D/I/C -- 0 C 0 C -- -- -- 4-97-288-91548

M33 X 2 [M] E 00

44 LBA02 CT 401 TW TEMP.AT SH MAIN STEAM LINE -R STEAM 1 D323.9X 31 138 148 Kg/cm2 540 555 0 C -- -- -- -- -- T -- 0 C -- -- -- -- 4-97-288-

91549M33 X 2 [M] -- 00

45 LAE10 CP 401 PP PR.AT SH SPY CNTRL STN. I/L WATER 1 D33.4X6.35 157.1 Kg/cm2 242 0 C -- -- -- -- -- T -- Kg/cm2 -- -- -- -- -- -- -- 00

46 LAE10 CP 501 PI PR.AT SH SPY CNTRL STN. I/L WATER 1 D33.4X6.35 157.1 Kg/cm2 242 0 C -- -- -- -- -- L/I -- 0-250 Kg/sq.cm -- --


-- -- M20 X 1.5[M] T 01

Drg. No:4-97-288-91644/01Page 3 of 4

2091445B

4006 & 4007 VOL D1 TAB-1-13



SL.N

O

TAG

-1

TAG

-2

TAG

-3

TYPE

OF

INST

DES

CR

IPTI

ON

MED

IUM

QTY

/ B

OIL

ER

LIN

E SI

ZE

OP.

PRES

S

MA

X.PR

ESS

UN

IT O

F PR

ESS

OP.

TEM

P

MA

X.TE

MP

UN

IT O

F TE

MP.

OP.

OTH

ERS.

MA

X. O

THER

S.

UN

IT O

F O

THER

S

MA

X. V

ELO

CIT

Y(m

/Sec

.)

INSU

LATI

ON

TH

ICK

NES

S(m

m)

FUN

CTI

ON

SET

POIN

T

RA

NG

E_ O

F_PY

_ IN

ST.

UN

IT_

OF_

PY_I

NST

RA

NG

E_O

F SE

C_I

NST

UN

IT_O

F_SE

C_I

NST

CO

NT.

AC

TIO

N

MA

KE

MO

DEL

TAPP

ING

PO

INT

D

ETA

IL/D

RG

.

INST

_EN

D_C

ON

N

CA

BLE

CO

NN

ECTI

ON

SCO

PE

REV

ISIO

N

REM

AR

KS

47 LAE10 CT 001 TE TEMP.AT SH SPY CNTRL STN. I/L WATER 1 D 168.3 X 21.95 157.1 Kg/cm2 242 0 C -- -- -- -- -- D/I -- Kg/cm2 -- -- -- -- 4-97-288-

91549M33 X 2 [M] E 01

48 LAE20 CP 401 PP PR.AT SPY WTR-DESH I/L WATER 1 D33.4X6.35 149.8 Kg/cm2 242 0 C -- -- -- -- -- T -- Kg/cm2 -- -- -- -- -- -- -- 00

49 LAE20 CF 002 FT FLOW AT SPY WR-DESH I/L WATER 1 D 21.3X 4.78 149.8 Kg/cm2 242 0 C 20 -- T/H

R -- -- D/I -- mmWC T/Hr -- -- -- --- --- E 00 FE BY BHEL(T)

50 LAE30 CP 401 PP PR.AT SPY WTR-DESH I/L WATER 1 D33.4X6.35 149.8 Kg/cm2 242 0 C -- -- -- -- -- T -- Kg/cm2 -- -- -- -- -- -- -- 00

51 LAE30 CF 002 FT FLOW AT SPY WR-DESH I/L WATER 1 D 21.3X 4.78 149.8 Kg/cm2 242 0 C 20 -- T/H

R -- -- D/I -- mmWC T/Hr -- -- -- --- --- E 01 FE BY BHEL(T)

52 LAE40 CP 501 PI PR.RH SPY CNTRL STN I/L WATER 1 D33.4X6.35 90 Kg/cm2 242 0 C -- -- -- -- -- L/ I -- 0-160 Kg/sq.cm -- --


-- -- M20 X 1.5[M] T 01

53 LAE40 CP 401 PP PR.RH SPY CNTRL STN I/L WATER 1 D33.4X6.35 90 Kg/cm2 242 0 C -- -- -- -- -- T -- Kg/cm2 -- -- -- -- --- -- 00

54 LAE40 CT 001 TE TEMP.AT RH SPY CNTRL STN. I/L WATER 1 D 73.0 X 9.53 90 Kg/cm2 242 0 C -- -- -- -- -- D/ I -- -- 4-97-288-

91549M33 X 2 [M] E 01

55 LAE51 CP 401 PP PR AT DOWNSTREAM OF SRPAY CONTROL VALVE WATER 1 D33.4X

6.35 90 Kg/cm2 242 -- 0 C -- -- -- -- -- T -- Kg/cm2 -- -- -- -- -- -- -- 00

56 LAE52 CP 401 PP PR AT DOWNSTREAM OF SRPAY CONTROL VALVE WATER 1 D33.4X

6.35 90 Kg/cm2 242 -- 0 C -- -- -- -- -- T -- Kg/cm2 -- -- -- -- -- -- -- 00

57 LAE51 CF 002 FT FLOW AT DOWNSTREAM OF SRPAY CONTROL VALVE WATER 1

D21.3X4.

7890 Kg/cm2 242 -- 0 C 8.13 -- T/H

R -- -- D/I -- mmWC T/Hr -- -- -- --- -- E 00 FE BY BHEL(T)

58 LAE52 CF 002 FT FLOW AT DOWNSTREAM OF SRPAY CONTROL VALVE WATER 1

D21.3X4.

7890 Kg/cm2 242 -- 0 C 8.13 -- T/H

R -- -- D/I -- mmWC T/Hr -- -- -- --- -- E 00 FE BY BHEL(T)

59 HAJ05 CT 001-002 TE TEMP.AT RH I/L HDR STEAM 2 D 406.4

X 17 35.2 42 Kg/cm2 349Train Ticke

0 C -- -- -- -- -- D/I -- 0 C 0 C -- -- -- 4-97-288-91548

M33 X 2 [M] E 00

60 HAJ10 CT 001-021 TE TEMP.(METAL) AT RH TUBES METAL 21 -- -- -- -- -- -- -- -- -- -- -- D/I 610 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] T 01

61 HCB10 CP 501 PI PR BEFORE SB PRV STEAM 1 D33.4X6.35 146 154.6 Kg/cm2 457 475 0 C -- -- -- -- -- L/ I -- 0-250 Kg/sq.cm --


-- -- M20 X 1.5[M] T 01

62 HCB10 CP 001-002 PT PR AFTER SB PRV STEAM 2 D33.4X

6.35 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- SB/I,C -- Kg/cm2 Kg/cm2 -- -- -- -- E 00 SBCP

63 HCB10 CP 502 PI PR AFTER SB PRV STEAM 1 D33.4X6.35 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- L/ I -- 0-60 Kg/sq.cm --


-- -- M20 X 1.5[M] T 01

64 HCB10 CF 201 FT FLOW AFTER SBPRV STEAM 1 D88.9X5.49 30 40 Kg/cm2 384 408 0 C -- -- -- -- SB/ I,C 1.8 /

2.2 * -- -- -- --- --- E 01 * wall blower/LRSB

65 HCB10 CP 201 PS PR AFTER SB PRV STEAM 1 D33.4X6.35 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- SB/ I,C 12 10 to

60 Kg/sq.cm COISWITZER

INSTRUMENT LTD

GM201-02-B2K-

55-ZT 01 PR.OK:SBCP

66 HCB10 CT 101 TE TEMP AFTER SB PRV STEAM 1 D60.3 X 3.91 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- SB/I -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00 SBCP

67 HCB20 CT 401 TW TEMP AT WB DRAIN LINE [FRONT&LEFT] STEAM 1 D60.3 X

3.91 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- T -- -- -- -- -- 4-97-288-91549

M33 X 2 [M] -- 00

68 HCB20 CT 101-102 TE TEMP AT WB DRAIN LINE

[FRONT&LEFT] STEAM 2 D60.3 X 3.91 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- SB/I,C -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00 SBCP

69 HCB30 CT 401 TW TEMP AT WB DRAIN LINE [REAR&RIGHT] STEAM 1 D60.3 X

3.91 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91549

M33 X 2 [M] -- 00

70 HCB30 CT 101-102 TE TEMP AT WB DRAIN LINE

[REAR&RIGHT] STEAM 2 D60.3 X 3.91 30 40 Kg/cm2 384 408 0 C -- -- -- -- -- SB/I,C -- 0 C 0 C -- -- -- 4-97-288-

91548M33 X 2 [M] E 00 SBCP

Drg. No:4-97-288-91644/01Page 4 of 4

2091445B

4006 & 4007 VOL D1 TAB-1-14

Bharat Heavy Electricals Limited

High Pressure Boiler Plant, Tiruchirapalli- 620 014 Controls & Instrumentation / FB

PROJECT: BHATINDA - R& M

2 X 120 MW UINIT – 3 & 4

RECOMMENDED WRITE UP ON INTERLOCKS AND PROTECTION

FOR BOILER HOUSE AUXILIARIES

[For Internal Circulation]

BCR NO: 501

PREPARED CHECKED APPROVED DATE DRAWING NO. REV

DEVAKUMAR P

R. PRIYA KALA

E.S.SALAI KUBERAN

04.09.07

4-97-096-91741

00

Sheet : 1 of 11

2091445B

4006 & 4007 VOL D1 TAB-1-15

Customer: M/s. Punjab State Electricity Board. Project: BHATINDA 2x120 MW Units # 3 & 4 R & M

DWG No 4-97-096-91741

REV

00

DATE

04/09/2007

Document: RECOMMENDED WRITE UP ON INTERLOCKS AND PROTECTION FOR BOILER HOUSE AUXILIARIES SHEET: 2 of 11

GENERAL: Today’s steam generators are larger in size and sophisticated in nature. Failure of any equipment calls for expensive replacement and results in costlier down time. This emphasises careful planning on the correct procedure for 1) Safe sequence of start-up of equipments in the power plant. 2) Continuous trouble free & efficient operation. 3) Safe sequence of shut down of the equipment when needed. This also leads to provision of adequate & reliable protection to safeguard the various plant equipments under abnormal and dangerous conditions. The operation of the protections shall be accompanied by visual and audible annunciation, which provide definite indication of the primary cause or causes of operation of the protection. Restarting of the equipment, which has once been tripped by protection either by remote, automatic or manual control shall be possible only after the elimination of the cause of tripping. PROTECTIONS ARE CLASSIFIED UNDER THREE GROUPS NAMELY; 1) Protection causing complete shut down of the unit. 2) Protection causing load reduction of the unit. 3) Protection causing annunciation only. 1. PROTECTIONS CAUSING COMPLETE SHUT DOWN OF THE UNIT a) Failure of all feed pumps (i.e.) reserve feed pump if any, fails to start on tripping of running pumps

even after a preset time delay. b) Boiler shut down due to failure of both FD fans, all ID fans and other conditions. c) Failure of Reheater protection, which is to ensure continuous steam flow through reheater tubes at,

specified conditions. 2. PROTECTION CAUSING LOAD REDUCTION a) ID fans: 2 ID fans are required for boiler MCR. If any one of the two running ID fans trips, the boiler

load shall be run down to 60% MCR b) FD fans: Any one of the two running FD fans trip, the boiler load shall be run down to 60% MCR. c) Mills, PA fans & coal Feeders: This reduces the boiler load correspondingly due to limitations in fuel

firing capabilities. 3. PROTECTIONS CAUSING ANNUNCIATION: The causes that lead to visual/audible annunciation are covered under various sub systems like FSSS, SADC, Sootblower control system, Auxiliary PRDS control system, Fuel oil system, Air & Flue gas system, Steam & water system etc. These interlocks & protection systems are divided into two portions based on the area they cover as briefly described below. a) Boiler auxiliaries interlock & protection: This system takes care of sequence of starting protection

and interlock of boiler auxiliaries like FD fans, ID fans, Dampers, Valves, etc. covered in this write up. b) Furnace safeguard supervisory system (FSSS): This system takes care of interlocks required for

starting, supervising the operating and safe shut down of the equipments connected with fuel firing system.

2091445B

4006 & 4007 VOL D1 TAB-1-16


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


BOILER HOUSE AUXILIARY INTERLOCKS: This Boiler is equipped with �� 2 ID fans with hydraulic coupling �� 2 FD fans �� 2 PA fans �� Tubular Air Heaters �� ERV �� 2 FTP’s �� FD &PA Fan Lube oil System. 1.0 ID FAN INTERLOCKS (FOR 2 FANS WITH HYDRAULIC COUPLING) 1.1 Conditions existing when the unit is shut down and prior to starting of ID fans. �� ID fan 'A' and ID fan 'B' OFF. �� Regulating vanes of fans A & B fully open �� Hydraulic coupling scoop tube in maximum position �� Inlet gates of ID fans A & B open �� Outlet gates of ID fans A & B open �� The regulating vanes will be on manual control during shutdown and signal from furnace draft control

to regulating vanes of ID fans & hydraulic coupling scoop tube are disconnected. 1.2 Starting ID Fan 'A' (ID fan 'B' OFF) ID fan 'A' shall be prohibited from starting till the following conditions are satisfied: �� Regulating vanes of ID Fan-A & Hydraulic coupling scoop tube in minimum position. �� Outlet gate of ID Fan-A closed. �� Inlet gate of ID Fan-A closed �� APH – Gas outlet Dampers –HNA 37 AA 001 & HNA 35 AA 001 – are in full open condition. �� ID Fan and Fan motor bearing temperature not very high. �� Motor winding temperature not very high �� Hydraulic coupling of FAN-A oil level OK (Manual check only) �� Cooler ready for operation (manual check only). When ID fan 'A' is started (ID Fan B is OFF), impulses shall be given for: �� Opening the inlet gate and outlet gate of ID fan A after the motor reaches rated speed. �� Connecting the regulating vanes/scoop tube control of ID fan A to the auto control after the following

conditions are satisfied 1. Fan-A hydraulic coupling oil filter DP is low 2. Fan-A hydraulic coupling control oil pressure is OK 3. Fan-A hydraulic coupling working oil temperature is low

�� Closing the inlet gate and the outlet gate of ID fan B and bringing the regulating vanes/scoop tube

control to minimum position. �� Permission to start either FD Fan A or FD Fan B.

2091445B

4006 & 4007 VOL D1 TAB-1-17


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


1.3 Starting ID fan B (ID Fan A is OFF) Interlocks similar to those at clause 1.2 shall hold good for this condition. 1.4 Tripping of ID Fan A (ID Fan B is OFF) a) ID fan 'A' shall trip automatically under following conditions. �� ID fan A bearing temperature too high (prior to this, ID fan A bearing temperature high shall be

annunciated in DDCMIS) �� ID fan a motor bearing/winding temp. Too high (prior to this, ID fan 'A' motor bearing/winding

temperature high shall be annunciated in DDCMIS) �� Fan –A Hydraulic

1. Coupling control oil pressure is very low (< 0.6 bar) 2. Coupling working oil temperature is very high ( >110 Deg. C) 3. Coupling oil cooler outlet temperature is very high

�� Post purge fan trip from FSSS �� ID fan A motor protection acted. b) When ID fan A trips (ID fan B is OFF) impulses shall be given for: �� Opening the outlet gate of ID fan B �� Opening the inlet gate of ID fan B. �� Disconnecting the impulse from auto control system (output from A/M station) to regulating vane and

scoop position. �� Opening the regulating vanes/scoop control of ID fan A & ID fan B to wide-open position. �� Tripping the working FD fans. �� Boiler tripping. �� To keep the inlet gate and outlet gate of ID fan A & ID fan B open 1.5 Tripping of ID fan B (ID fan A is OFF): Interlocks similar to those at clause 1.4 shall hold good for this condition 1.6 Starting of ID fan B (ID fan A is ON) a) ID fan B shall be prohibited from starting unless the following conditions are satisfied: �� Outlet gate of fan B is closed �� Inlet gate of fan B is closed �� Regulating vanes/scoop of fan B are in minimum position �� APH – Gas outlet Dampers –HNA 37 AA 001 & HNA 35 AA 001 – are in full open condition. �� Fan and Fan motor bearing temperature not very high �� Motor winding temperature not very high �� Hydraulic coupling of FAN-B oil level OK (Manual check only) �� Cooler ready for operation (manual check only). b) When ID fan B is started, impulses shall be given for: �� Opening the inlet gate and outlet gate of fan B after the motor reaches the rated speed �� Connecting the regulating vanes/scoop of fan B to auto control (release to auto) after the following

conditions are satisfied

2091445B

4006 & 4007 VOL D1 TAB-1-18


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


1. Fan-B hydraulic coupling oil filter DP is low 2. Fan-B hydraulic coupling control oil pressure is OK 3. Fan-B hydraulic coupling working oil temperature is low

�� Permission to start other FD fan. 1.7 Starting of ID fan A (ID Fan B is ON): Interlocks similar to those at clause 1.6 shall hold good for this condition. 1.8 Tripping of ID fan B (ID fan A is ON) (a) ID fan B shall trip automatically under the following conditions: �� Fan bearing temperature too high (prior to this fan bearing temperature high shall be annunciated in

DDCMIS) �� Fan motor bearing/winding temperature too high (prior to this fan motor bearing/winding temperature

high shall be annunciated in DDCMIS) [Set Point for fan Bearing Temperature interlock: Trip: > 105 dec C Alarm: > 95 dec C]

�� Post purge fan trip from FSSS �� ID fan B motor protection acted. �� Fan – B Hydraulic

1. Coupling control oil pressure is very low 2. Coupling working oil temperature is very high 3. Coupling oil cooler outlet temperature is very high

b. When ID Fan B trips (ID fan A is ON) impulses shall be given for: �� Disconnecting the regulator from acting on the regulating vane/scoop of ID Fan B. �� Bringing the regulating vane of Fan B to the minimum position and Scoop to maximum position �� Closing the inlet gate of ID Fan B �� Closing the outlet gate of ID fan B �� Tripping the FD fan B, provided FD fan A is on �� Energisation of partial load relay (load to be limited to 60%) 1.9 Tripping of ID fan A (ID fan is ON):

Interlocks similar to those at clause 1.8 shall hold good for this condition. 2.0 FD FAN INTERLOCKS �� Ref : Lub. Oil Scheme for FD Fan –2-00-098-21614. 2.1 Conditions prior to starting FD fans: �� FD Fan A and FD Fan B off �� Fan impellers tilted to maximum opening �� Outlet dampers are fully open �� Fan impeller regulator disconnected from Auto control. �� Lube oil pumps of FD fans off 2.2 Starting FD fan A (FD fan B is off): a) FD Fan A shall be prohibited from starting until the following conditions are satisfied:

2091445B

4006 & 4007 VOL D1 TAB-1-19


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


�� ID Fan A or ID Fan B is on �� Control oil pressure adequate [ > 8 ATA] & lub. Oil pressure adequate [ > 0.8 ATA] (control oil

pressure adequate lamp indication shall be provided on the control desk) �� Fan A impeller tilt in the minimum position �� Outlet damper of fan A in closed position �� Fan/motor bearing temperature not very high �� Motor winding temperature not very high b) When FD fan A is started (FD Fan B is off) impulses shall be given for: �� Outlet damper of fan A to open after the motor reaches rated speed �� The outlet damper of FD fan B to close & impeller blades of fan B to be driven to minimum position �� Connecting the impeller of Fan A control drive to auto control 2.3 Starting of FD fan B (FD fan A is off): Interlocks similar to those at clause 2.2 shall hold good for this condition. 2.4 Tripping of FD fan A (FD fan B is off) a) FD fan A shall trip automatically under the following conditions: �� FD fan A bearing temperature too high (prior to this, FD fan A bearing temperature high will be

annunciated in DDCMIS) [ Set Point: Trip: > 105 dec C Alarm: > 95 dec C] �� FD fan A motor bearing/winding temperature too high (prior to this, FD fan A motor temperature high

will be annunciated in DDCMIS) �� Both ID fans trip �� Post purge fan trip �� FD fan A motor protection acted Note: If control Oil Pressure < 6 ATA or lub. Oil Pressure < 0.4 ATA it shall be annunciated in DDCMIS b) When FD Fan A trips (FD fan B is off) impulses shall be given for: �� Disconnecting the impeller control drive from auto control system (output signal from A/M station) �� Bringing the impeller of Fan A to the maximum position �� Bringing the impeller of FD fan B to the maximum position �� Opening the outlet damper of FD fan B �� Open the emergency scanner air damper �� Boiler tripping �� The outlet damper of FD fan A shall remain open �� Tripping of running ID fans 2.5 Tripping FD fan B (FD fan A is off): Interlocks similar to those of clause 2.4 shall hold good for this condition 2.6 Starting FD fan B (FD fan A is on): a) FD fan B (FD fan A is on) shall be prohibited from starting until the following conditions are satisfied:

2091445B

4006 & 4007 VOL D1 TAB-1-20


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


�� Both ID fans are on �� Control oil pressure adequate [ > 8 ATA] & lub. Oil pressure adequate [ > 0.8 ATA] (control oil & lube

Oil adequate lamp indication shall be provided on control desk) �� Fan B impeller tilt in the minimum position �� Outlet damper of Fan B in closed position �� Fan and fan motor bearing temperature not very high �� Motor winding temperature not very high. b) When FD fan B is started (FD fan A is on) impulses shall be given for: �� Opening the outlet damper of FD fan B after the motor reaches rated speed �� Connecting the impeller control drive of FD fan B to auto control 2.7 Starting FD fan A (FD fan B is on): Interlocks similar to those at clause 2.6 shall hold good for this condition 2.8 Tripping of FD fan B (FD fan A is on): a) FD fan B shall trip (FD fan A is on) under the following conditions: �� ID fan B trips �� FD fan B motor bearing/winding temperature too high (prior to this, FD fan B motor bearing/winding

temperature high shall be annunciated in DDCMIS) �� FD fan B bearing temperature too high (prior to this, FD fan B bearing temperature high shall be an

annunciated in DDCMIS) [Set Point: Trip: > 105 dec C Alarm: > 95 dec C] �� FD fan B motor protection acted Note: If control oil Pressure < 6 ATA or lub. Oil Pressure < 0.4 ATA it shall be annunciated in DDCMIS b) When FD fan B trips (FD fan A is on), impulses shall be given for: �� Disconnecting regulator impulse from acting on impeller control drive of fan B �� Bringing impeller of fan B to the minimum position �� Closing the outlet damper of fan B �� Energisation of partial load relay to reduce boiler load to 60% MCR. �� Tripping mills working more than three through FSSS 2.9 Tripping of FD fan A (FD fan B is on): Interlocks similar to those at clause 2.8 shall hold good for this condition. 3.0 PA FAN INTERLOCKS: 3.1 Conditions prior to start up �� PA fan A and PA fan B off �� Outlet gates of fan A and fan B closed �� Regulating vanes of fan A and fan B in closed position. �� Regulating vane regulator disconnected �� Lub. Oil pumps are off

2091445B

4006 & 4007 VOL D1 TAB-1-21


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


3.2 Starting PA fan A (PA fan B off) a) PA fan A (PA fan B off) shall be prohibited from starting until the following conditions are satisfied: �� Regulating vanes of PA Fan A in the minimum position �� Outlet gate of PA fan A in closed position �� Any one FD fans is on �� Purge complete �� PA fan and fan motor bearing temperature not very high �� Lub. Oil pressure adequate. Note: Signal from PA fan A start pushbutton shall simultaneously go to start PA fan A and seal air fan A

b) When PA fan A is started (PA fan B is off), impulses shall be given for: �� Opening the outlet gate of PA Fan A after the motor reaches rated speed �� Connecting the regulating vanes of PA fan A to auto control �� Bringing the regulating vanes of PA fan B to the minimum position �� Closing the outlet damper of PA fan B �� Permission to start any three mills through FSSS. 3.3 Starting PA fan B (PA fan A is off) Interlocks similar to those at clause 3.2 shall hold good for this condition 3.4 PA fan A shall trip(PA fan B is off) a) PA fan A shall trip (PA fan B is off) under the following conditions:

�� PA fan A bearing temperature too high (prior to this bearing temperature high shall be annunciated in

DDCMIS) [ Set Point: Trip: > 82 dec C Alarm: > 77 dec C ] �� PA fan A motor bearing/winding temperature too high (prior to this, motor bearing/winding

temperature high shall be annunciated in DDCMIS) �� Boiler trips �� PA fan A motor protection acted

b) When PA fan A trips (PA fan B is off), impulses shall be given for: �� Disconnecting the regulating vanes of PA fan A from auto control �� Bringing the regulating vanes of PA fan A to minimum position �� Closing the outlet gate of PA fan A �� Closing the outlet gate of PA fan B �� Bringing the regulating vane PA fan B to minimum position �� Tripping all the operating mills (done through FSSS) 3.5 Tripping of PA fan B (PA fan A is off) Interlocks similar to those at clause 3.4 shall hold good for this condition 3.6 Starting PA fan B (PA fan A is on) a) PA fan B shall be prohibited from starting unless the following conditions are satisfied:

2091445B

4006 & 4007 VOL D1 TAB-1-22


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


�� Both FD fans are on �� Regulating vanes of PA fan B in the minimum position �� Outlet gate of PA fan B in closed position �� PA fan B and fan motor bearing temperature not very high �� Lube. Oil pressure adequate. [ > 0.8 ATA]

b) When PA fan B is started (PA fan A is on) impulses shall be given for: �� Opening the outlet gate of PA fan B after the motor reaches rated speed �� Connecting the regulating vanes of PA fan B to auto control �� Permission to start three more mills through FSSS 3.7 Starting PA fan A (PA fan B is on) Interlocks similar to those at clause 3.6 shall hold good for this condition 3.8 Tripping of PA fan B (PA fan A is on) a) PA fan B shall trip (PA fan A is on) under the following conditions: �� PA fan B bearing temperature too high (prior to this, fan bearing temperature high shall be

annunciated in DDCMIS) [Set Point: Trip: > 82 dec C Alarm: > 77 dec C] �� PA fan B motor bearing/winding temperature too high (prior to this, fan motor bearing/winding

temperature high shall be annunciated in DDCMIS) �� Boiler trips �� PA fan B motor protection

b) When PA fan B trips (PA fan A is on), impulses shall be given for: �� Disconnecting the regulating vanes of PA fan B from auto control �� Bringing the regulating vanes of PA fan B to minimum position �� Closing the outlet gate of PA fan B �� Energisation of partial load relay (load to be limited to 60%) 3.9 Tripping of PA fan A (PA fan B is on) Interlocks similar to those at clause 3.8 shall hold good for this condition. 3.10 Both the PA fans shall trip simultaneously when any boiler trip condition is present (impulses from FSSS). 4.0 INTERLOCKS FOR FD FAN LUBRICATING/CONTROL OIL SYSTEM: 4.1 FD fan A lube oil/control oil system: REF : Lube oil scheme for Forced Draft Fan Dwg No : 2-00-098-21614 (a) Pump A will start automatically if pump B trips, provided A/M switch is in auto position Pump A will start automatically with a time delay of 0-60 seconds if lube oil pressure falls below a set value <5 ata and the pump B is working provided A/M switch is in auto position. (b) PUMP B will start automatically if pump A trips, provided A/M switch is in auto position.

2091445B

4006 & 4007 VOL D1 TAB-1-23


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


Pump B will start automatically with a time delay of 0-60 seconds if lube oil pressure falls below a set value <5 ata and the pump A is working provided A/M switch is in auto position. (c) Pump A or pump B can be started/tripped by pressing the respective push button provided on local push button box only when A/M switch is in manual position. (d) FD fan A shall be prohibited from starting until the control oil pressure is adequate [> 8 ATA] 4.2 FD fan B lubricating oil system: Interlocks similar to those at 5.1 (a), (b), (c) and (d) above shall hold good for FD fan B lubricating oil system. 5.0 Interlock for PA fan lubricating oil system REF : Lube oil scheme for Forced Draft Fan Dwg No : 2-00-098-21615 Interlocks similar to 4.0 shall hold good for PA fan lube oil system, (Except the lube oil pressure set < 0.6

ata for auto start). 6.0 FURNACE TEMPERATURE PROBE �� Furnace temperature probe can be advanced/retracted using the push buttons provided in DCS as

well as from site. �� Furnace temperature probe shall be prohibited from being advanced further into the furnace if

furnace temperature sensed by it is more than 540 o C �� If furnace temperature probe is inside the furnace and the temperature exceeds 540 0 C it will be

retracted back automatically. 7.0 ELECTROMATIC RELIEF VALVE : Ref : Write up on ERV Control and ERV control Interconnection Diagram 3-97-597-14693.

�� The electromatic Relief Valve is an automatic, electrically actuated pressure relief valve. �� ERV’s can be operated using the Push buttons ‘AUTO’ and ‘Manual’ provided in DCS. 8.0 MISCELLANEOUS INTERLOCKS: 8.1 Interlock and protection write-up for DDI gate with motor operated blowers motor: 8.1.1 Guillotine Gate with motor operated blower & manual isolation valve for blower: [HNC 10&20 AA 003]

�� Gate will close and open according to BHA interlock and protection. �� Blower shall be continuously working irrespective of whether the gate is in close or open

position, when boiler is working. �� The manual isolation valve in the blower line shall always be open. �� If the blower trips due to overload, it shall be annunciated.

Note: The blower motor for ID fan outlet gate shall be started simultaneously with ID fan 8.1.2 Interlocks for Guillotine Gate without motor operated blowers but with manual isolation

valve are as per BHA interlock and protection requirement.

�� The manual isolation valve in the blower line shall always be open.

2091445B

4006 & 4007 VOL D1 TAB-1-24


DWG No 4-97-096-91741

REV

00

DATE

04/09/2007


8.2.0 Interlocks for motor operated valves with Bypass valves:

��First open the bypass valve fully ��After bypass valve is fully opened, Main valve may or may not be closed. ��Main valve can be closed wherever required. The bypass valve, if not already closed, can be

closed when main valve is commanded to close. 8.3.0 Interlocks for valves with integral bypass: a. The main valve shall not open unless its motorised integral bypass valve is in fully open position. b. The motorised integral bypass valve shall close simultaneously when its main valve is closed. 9.0 MOTOR OPERATED VALVE INTERLOCK REQUIREMENTS GATE VALVES OF 100mm and above in 1500 CL and above Ratings. Valve closing / opening:

Actuator motor tripping shall be done by limit switch. Torque switch shall be used as a backup in the control circuit.

ALL OTHER GATE & GLOBE VALVES: Valve closing:

Actuator motor tripping shall be done by torque switch. Limit switch shall not be used in the control circuit for tripping.

Valve opening:

Actuator motor tripping shall be done by limit switch. Torque switch shall be used in the control circuit as a back up.

Thermostat shall be connected without fail in the starter circuit.

10 REHEATER PROTECTION LOGIC:

Re-heater protection shall be provided as part of Boiler House Auxiliaries Interlock and protection system. This protection is provided to protect the Re-heater against starvation of steam flow during abnormal conditions. To take care of Re-heater protection, the Boiler shall be tripped after 10 seconds, when any of the following conditions occur: 1) When Boiler is working and if (i) Generator circuit breakers open and (ii) HP Bypass or LP Bypass valves remain closed less than 2% 2) When Boiler is working and if (i) Turbine trips and (ii) HP Bypass or LP Bypass valves remain closed less than 2% Recommended Re-heater Protection Logic is enclosed. – ANNEXURE A

2091445B

4006 & 4007 VOL D1 TAB-1-25

2091445B

4006 & 4007 VOL D1 TAB-1-26

2091445B

4006 & 4007 VOL D1 TAB-1-27


MEASUREMENT AND CONTROL RECOMMENDATIONS FOR AIR AND FLUE GAS SYSTEM

BCR 590

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35SL

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01 HFE10 CP 401 PP PR. AT PAF-A SUC PY.AIR 1 -- -12 -13 mm WC 30 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

02 HFE10 CT 501 TI TEMP. AT PAF-A MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

03 HFE10 CT 001 TE TEMP. AT PAF-A MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

04 HFE10 CT 002-013 TE TEMP. AT PAF-A MTR WNDG METAL 12 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- --- -- -- R 00

05 HFE10 CT 502 TI TEMP. AT PAF-A MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

06 HFE10 CT 014 TE TEMP. AT PAF-A MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

07 HFE10 CT 015 TE TEMP. AT PAF-A NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

08 HFE10 CT 503 TI TEMP. AT PAF-A NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

09 HFE10 CT 504 TI TEMP. AT PAF-A DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

10 HFE10 CT 016 TE TEMP. AT PAF-A DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

11 HFE10 CT 401 TP TEMP. AT PAF-A O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

12 HFE10 CP 402 PP PR. AT PAF-A O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

13 HFE10 CP 001 PT PR. AT PAF-A O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

14 HFE10 CT 017 TE TEMP. AT PAF-A O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

15 HFE20 CP 401 PP PR. AT PAF-B SUC PY.AIR 1 -- -12 -13 mm WC 30 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

16 HFE20 CT 501 TI TEMP. AT PAF-B MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

17 HFE20 CT 001 TE TEMP. AT PAF-A MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

18 HFE20 CT 502 TI TEMP. AT PAF-B MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

19 HFE20 CT 002-013 TE TEMP. AT PAF-B MTR WNDG METAL 12 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- --- -- -- R 00

20 HFE20 CT 014 TE TEMP. AT PAF-B MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

21 HFE20 CT 015 TE TEMP. AT PAF-B NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

22 HFE20 CT 503 TI TEMP. AT PAF-B NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

23 HFE20 CT 504 TI TEMP. AT PAF-B DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

24 HFE20 CT 016 TE TEMP. AT PAF-B DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

25 HFE20 CT 401 TP TEMP. AT PAF-B O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

26 HFE20 CP 402 PP PR. AT PAF-B O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

27 HFE20 CP 001 PT PR. AT PAF-B O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

28 HFE20 CT 017 TE TEMP. AT PAF-B O/L PY.AIR 1 1400 X 1400 900 943 mm WC 35 55 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

29 HFE30 CP 401 PP PR. AT AH I/L PY.AIR 1 2000 X 2000 882 923 mm WC 35 55 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

DRG.NO.4-97-288-91646/01SHEET 2 OF 71

2091445B

4006 & 4007 VOL D1 TAB-1-28



BCR 590

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35SL

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30 HFE30 CT 401 TP TEMP. AT AH I/L PY.AIR 1 2000 X 2000 882 923 mm WC 35 55 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

31 HFE30 CT 001 TE TEMP. AT AH I/L PY.AIR 1 2000 X 2000 882 923 mm WC 35 55 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

32 HFE30 CP 001 PT TEMP. AT AH I/L PY.AIR 1 2000 X 2000 882 923 mm WC 35 55 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91550 -- -- E 00

33 HFE35 CP 401 PP PR. AT PAH O/L PY.AIR 1 2000 X 2000 798 833 mm WC 228 270 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

34 HFE35 CT 401 TP TEMP. AT PAH O/L PY.AIR 1 2000 X 2000 798 833 mm WC 228 270 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

35 HFE35 CP 001 PT PR. AT PAH O/L PY.AIR 1 2000 X 2000 798 833 mm WC 228 270 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

36 HFE35 CT 001 TE TEMP. AT PAH O/L PY.AIR 1 2000 X 2000 798 833 mm WC 228 270 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

37 HLB 10 CP 401 PP PR. AT FD FAN - A SUC SEC AIR 1 -- -18 mm WC 30 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

38 HLB 10 CT 501 TI TEMP. AT FD FAN - A MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

39 HLB 10 CT 001 TE TEMP. AT FDF-A MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

40 HLB 10 CT 002-113 TE TEMP. AT FDF-A MTR WNDG METAL 12 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- --- -- -- R 00

41 HLB 10 CT 502 TI TEMP. AT FDF-A MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

42 HLB 10 CT 014 TE TEMP. AT FDF-A MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

43 HLB 10 CT 015-016 TE TEMP. AT FDF-A BRG. METAL 2 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 95/ 105 0C 0C -- -- -- --- -- -- R 00

44 HLB 10 CT 503 TI TEMP. AT FDF-A BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

45 HLA 10 CT 401 TP TEMP. AT FDF-A O/L SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

46 HLA 10 CP 401 PP PR. AT FDF-A O/L SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

47 HLA 10 CP 001 PT PR. AT FDF-A O/L SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

48 HLA 10 CT 003 TE TEMP. AT FDF-A O/L SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- 4-97-288-91551 -- -- E 00

49 HLA10 CT 402 TP TEMP. AT AH-A I/L SEC AIR 1 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

50 HLA10 CP 402 PP PR. AT AH-A I/L SEC AIR 1 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

51 HLA10 CT 001-002 TE TEMP. AT AH-A I/L SEC AIR 2 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

52 HLA10 CP 002 PT PR. AT AH-A I/L SEC AIR 1 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

53 HHL10 CP 401 PP PR. AT AH-A O/L SEC AIR 1 153 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

54 HHL10 CT 401 TP TEMP. AT AH-A O/L SEC AIR 1 153 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

55 HHL10 CT 001 TE TEMP. AT AH-A O/L SEC AIR 1 153 mm WC 255 275 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

56 HHL10 CP 001 PT PR. AT AH-A O/L SEC AIR 1 153 mm WC 255 275 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

57 HHL10 CF 001-003 FT FLOW AT SEC. AIR - L SEC AIR 3 134 mm WC 255 275 0C 162 T/HR -- -- D / I, C -- mmWC t/hr -- -- -- E 00

58 HHL10 CT 002-004 TE SEC. AIR TEMP - L SEC AIR 3 134 mm WC 255 275 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

59 HHL10 CP 402 PP PR. AT WB - L SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

60 HHL10 CT 402 TP TEMP. AT WB - L SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

61 HHL10 CP 403 PP PR. AT WB - L SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

DRG.NO.4-97-288-91646/01SHEET 3 OF 71

2091445B

4006 & 4007 VOL D1 TAB-1-29



BCR 590

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35SL

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62 HHL10 CT 403 TP TEMP. AT WB - L SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

63 HHL10 CP 002 PT PR. AT WB - L SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

64 HLB 20 CP 401 PP PR. AT FD FAN - B SUC SEC AIR 1 -- -18 mm WC 30 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

65 HLB 20 CT 501 TI TEMP. AT FD FAN - B MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

66 HLB 20 CT 001 TE TEMP. AT FDF-B MTR NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

67 HLB 20 CT 002-113 TE TEMP. AT FDF-B MTR WNDG METAL 12 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- --- -- -- R 00

68 HLB 20 CT 014 TE TEMP. AT FDF-B MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

69 HLB 20 CT 502 TI TEMP. AT FDF-B MTR DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

70 HLB 20 CT 015-016 TE TEMP. AT FDF-B BRG. METAL 2 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 95/ 105 0C 0C -- -- -- --- -- -- R 00

71 HLB 20 CT 503 TI TEMP. AT FDF-B BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

72 HLA 20 CT 401 TP TEMP. AT FDF-B O/R SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

73 HLA 20 CP 401 PP PR. AT FDF-B O/R SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

74 HLA 20 CP 001 PT PR. AT FDF-B O/R SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

75 HLA 20 CT 003 TE TEMP. AT FDF-B O/L SEC AIR 1 1850 X1850 317 mm WC 33 50 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- 4-97-288-91551 -- -- E 00

76 HLA 20 CT 402 TP TEMP. AT AH-B I/R SEC AIR 1 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

77 HLA 20 CP 402 PP PR. AT AH-B I/R SEC AIR 1 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

78 HLA 20 CT 001-002 TE TEMP. AT AH-B I/R SEC AIR 2 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

79 HLA 20 CP 002 PT PR. AT AH-B I/R SEC AIR 1 1850 X1850 291 mm WC 33 50 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

80 HHL20 CP 401 PP PR. AT AH-B O/R SEC AIR 1 1900 X1900 153 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

81 HHL20 CT 401 TP TEMP. AT AH-B O/R SEC AIR 1 1900 X1900 153 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

82 HHL20 CT 001 TE TEMP. AT AH-B O/R SEC AIR 1 1900 X1900 153 mm WC 255 275 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

83 HHL20 CP 001 PT PR. AT AH-B O/R SEC AIR 1 1900 X1900 153 mm WC 255 275 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

84 HHL20 CF 001-003 FT FLOW AT SEC. AIR - R SEC AIR 3 1900 X1900 134 mm WC 255 275 0C 162 T/HR -- -- D / I, C -- mmWC t/hr -- -- -- E 00

85 HHL20 CT 002-004 TE SEC. AIR TEMP - R SEC AIR 3 1900 X1900 134 mm WC 255 275 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

86 HHL20 CP 402 PP PR. AT WB - R SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

87 HHL20 CT 402 TP TEMP. AT WB - R SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

88 HHL20 CP 403 PP PR. AT WB - R SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

89 HHL20 CT 403 TP TEMP. AT WB - R SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

90 HHL20 CP 002 PT PR. AT WB - R SEC AIR 1 100 mm WC 255 275 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

91 HHQ10 CP 101 PDSL DP ACROS SCA. AIR FTR SCA AIR 1 -- mm WC 0C DP=10 -- -- -- -- D/A 4 0 to 50 mmWC -- CODSWITZERINSTRUMENTLTD

GM306-02-B5D-DD-Z

1/2" NPT-F

3/4"NPT-F T 01

92 HHQ10 CP 102 PDSH DP ACROS SCA. AIR FTR SCA AIR 1 -- mm WC 0C DP=10 -- -- -- -- D/A 15 0-50 mmWC mmWC COISWITZERINSTRUMENTLTD

GM306-02-B5D-DD-Z

1/2" NPT-F

3/4"NPT-F T 01

93 HHQ10 CP 001 PDT DP ACROS SCA. AIR FTR SCA AIR 1 -- mm WC 0C DP=10 -- -- -- -- D / I -- mmWC mmWC -- -- -- E 00

DRG.NO.4-97-288-91646/01SHEET 4 OF 71

2091445B

4006 & 4007 VOL D1 TAB-1-30



BCR 590

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94 HHQ11 CP 401 PP PR. AT SCA. AIR FAN I/L SCA AIR 1 -- 317 mm WC 33 50 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

95 HHQ40 CP 001 PT PR. AT SCA. AIR FAN O/L SCA AIR 1 -- 517 mm WC 33 50 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

96 HHQ40 CP 402 PP PR. AT SCA. AIR FAN O/L SCA AIR 1 -- 517 mm WC 33 50 0C -- -- -- -- -- T -- mmWC -- -- 4-97-288-91550 -- -- -- 00

97 HHQ40 CP 101 PDSL DP ACROS SCA. AIR/FURN. SCA AIR /FLUE GAS 1 -- 517/-5 -- mm WC 33/1155 -- 0C DP -- -- -- -- F/N 150 50-1200 mmWC mmWC COD

SWITZERINSTRUMENTLTD

GM301-02-EIDDD-Z

1/2" NPT-F

3/4"NPT-F T 01

98 HHQ40 CP 001 PDT DP ACROS SCA. AIR/FURN. SCA AIR /FLUE GAS 1 -- 517/-5 -- mm WC 33/1155 -- 0C DP -- -- -- -- D / I mmWC mmWC -- -- -- E 00

99 HBK10 CP 001 PDT DP ACROS WB & FURN-L SEC AIR FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C DP -- -- -- -- SA/I,C -- mmWC mmWC -- -- -- E 00

100 HBK10 CP 101-102 PSHH PR. AT FURN -L FLUE GAS 2 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- F/I/N +15040mmHg-0-0.05kg/sq.cm

mmWC COI SOR INC

52RN-EE116-M4-C2A-TTYYW-PKA7X

4-97-288-91546 1/2"NPT(F)

3/4"NPT(F) T 01

101 HBK 10 CP 103-104 PSLL PR. AT FURN -L FLUE GAS 2 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- F/I N -17540 mmHg - 0 - 0.05 K /S

mmWC mmWC COD SOR INC52RN-EE116-M4-C2A-TTYYVV

4-97-288-91546 1/2"NPT(F)

3/4"NPT(F) T 01

102 HBK 10 CP 105 PDSH DP ACROS WB & FURN-R FLUE GAS/SEC AIR 1 -- -4 -- mm WC 1155 1160 0C DP -- -- -- -- D/A +150 mmWC mmWC COI 1/2" NPT-

F3/4"

NPT-F E 01

103 HBK 10 CP 401 PP PR. AT FURN -L FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91546 -- -- -- 00

104 HBK 10 CT 401 TP TEMP. AT FURN - L FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91547 -- -- - 00

105 HBK 10 CP 001-002 PT PR. AT FURN -L FLUE GAS 2 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- D/I,C -- mmWC mmWC -- 4-97-288-91546 -- -- E 00

106 HBK20 CP 101 PSAH PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- F/ A 75 (-)200to200 mmWC mmWC COISWITZERINSTRUMENTLTD

GM204-02-X9K-DD-Z 4-97-288-91546 1/2"

NPT(F)3/4"

NPT(F) T 01

107 HBK20 CP 401 PP PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91546 -- -- -- 00

108 HBK20 CP 102 PSHH PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- F/I/N +15040mmHg-0-0.05kg/sq.cm

mmWC COI SOR INC


4-97-288-91546 1/2"NPT(F)

3/4"NPT(F) T 01

109 HBK20 CP 103 PSAL PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- F/ A -100 (-)200to200 mmWC mmWC CODSWITZERINSTRUMENTLTD

GM204-02-X9K-DD-Z 4-97-288-91546 1/2"

NPT(F)3/4"

NPT(F) T 01

110 HBK20 CP 104 PSLL PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- F/I N -17540mmHg-0-0.05kg/sq.cm

mmWC COD SOR INC


4-97-288-91546 1/2"NPT(F)

3/4"NPT(F) T 01

111 HBK20 CP 001 PDT DP ACROS WB & FURN-R FLUE GAS/SEC AIR 1 -- -4 -- mm WC 1155 1160 0C DP -- -- -- -- SA/I,C,N mmWC mmWC -- -- -- E 00

112 HBK20 CP 001-002 PT PR. AT FURN -R FLUE GAS 2 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- D/I,C150,(-)175, 75, (-)100

mmWC mmWC -- 4-97-288-91546 -- -- E 00

113 HBK20 CP 401 TP PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91547 -- -- -- 00

114 HBK20 CP 402 PP PR. AT FURN -R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91546 -- -- -- 00

115 HBK10 CT 402 TP TEMP. AT FURN O/L - L FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91547 -- -- - 00

116 HBK10 CT 001 TE TEMP. AT FURN O/L - L (FTP) FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91547 -- -- T 01

117 HBK20 CT 402 TP TEMP. AT FURN - R FLUE GAS 1 -- -4 -- mm WC 1155 1160 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91547 -- -- - 00

118 HBK30 CP 401 PP PR. AT PSH O/L -L FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

119 HBK30 CT 001 TE TEMP. AT PSH O/L-L FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

120 HBK30 CT 401 TP TEMP. AT PSH O/L-L FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

121 HBK35 CP 401 PP PR. AT PSH O/L -R FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

122 HBK35 CP 001 PT PR. AT PSH O/L -R FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

123 HBK35 CT 401 TP TEMP. AT PSH O/L-R FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

DRG.NO.4-97-288-91646/01SHEET 5 OF 71

2091445B

4006 & 4007 VOL D1 TAB-1-31



BCR 590

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124 HBK35 CT 001 TE TEMP. AT PSH O/L-R FLUE GAS 1 -- -5 -5 mm WC 1058 1060 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- E 01

125 HBK40 CP 401 PP PR. AT RH O/L -L FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

126 HBK40 CP 001 PT PR. AT RH O/L -L FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

127 HBK40 CT 401 TP TEMP. AT RH O/L -L FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

128 HBK40 CT 001 TE TEMP. AT RH O/L -L FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- E 01

129 HBK45 CP 401 PP PR. AT RH O/L -R FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

130 HBK45 CT 001 TE TEMP. AT RH O/L -R FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

131 HBK45 CT 401 TP TEMP. AT RH O/L -R FLUE GAS 1 -- -8 -8 mm WC 941 945 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

132 HBK50 CP 401 PP PR. AT LTSH O/L -L FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

133 HBK50 CP 001 PT PR. AT LTSH O/L -L FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

134 HBK50 CT 401 TP TEMP. AT LTSH O/L -L FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

135 HBK50 CT 001 TE TEMP. AT LTSH O/L -L FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- E 01

136 HBK55 CP 401 PP PR. AT LTSH O/L -R FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

137 HBK55 CT 001 TE TEMP. AT LTSH O/L -R FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

138 HBK55 CT 401 TP TEMP. AT LTSH O/L -R FLUE GAS 1 -- -15 -16 mm WC 748 750 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

139 HNA10 CP 401 PP PR. AT ECO O/L - L FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

140 HNA10 CQ 401 AP ANAL. AT ECO O/L - L FLUE GAS 1 -66 -68 mm WC 302 304 0C 3.54 -- -- -- -- T -- -- -- -- 4-97-288-91552 -- -- - 00

141 HNA10 CT 401 TP TEMP. AT ECO O/L- L FLUE GAS 1 -66 -68 mm WC 302 304 0C 3.54 -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

142 HNA10 CT 001 TE TEMP. AT ECO O/L- L FLUE GAS 1 -66 -68 mm WC 302 304 0C 3.54 -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- E 00

143 HNA15 CP 401 PP PR. AT ECO O/L - R FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

144 HNA15 CP 001 PT PR. AT ECO O/L-R FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

145 HNA15 CQ 401 AP ANAL. AT ECO O/L - R FLUE GAS 1 -66 -68 mm WC 302 304 0C 3.54 -- -- -- -- T -- -- -- -- 4-97-288-91552 -- -- - 00

146 HNA15 CT 401 TP TEMP. AT ECO O/L -R FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

147 HNA30 CP 401 PP PR. AT ECO O/L - R FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

148 HNA30 CT 401 TP TEMP. AT ECO O/L -R FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

149 HNA30 CP 001 PT PR. AT ECO O/L-R FLUE GAS 1 -66 -68 mm WC 302 304 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

150 HNA10 CQ 001 AT O2 ANAL AT SAH - A I/L FLUE GAS 1 -71 -73 mm WC 0C 3.54 -- -- -- -- D / I --% BY DRYVOL

% BY DRYVOL

-- --- -- 4-97-288-91552 -- -- E 00

151 HNA10 CQ 401 AP ANAL AT SAH A I/L FLUE GAS 1 -71 -73 mm WC 0C 3.54 -- -- -- -- T -- -- -- -- 4-97-288-91552 -- -- - 00

152 HNA10 CT 001 TE TEMP. AT SAH-A I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

153 HNA10 CT 401 TP TEMP. AT SAH-A I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

154 HNA10 CP 401 PP PR. AT SAH-A I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

155 HNA15 CQ 001 AT O2 ANAL AT SAH - B I/L FLUE GAS 1 -71 -73 mm WC 0C 3.54 -- -- -- -- D / I --% BY DRYVOL

% BY DRYVOL

-- --- -- 4-97-288-91552 -- -- E 00

156 HNA15 CQ 402 AP ANAL. AT SAH - B I/L FLUE GAS 1 -71 -73 mm WC 0C 3.54 -- -- -- -- T --% BY DRYVOL

% BY DRYVOL

-- 4-97-288-91552 -- -- - 00

157 HNA15 CT 001 TE TEMP. AT SAH B I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

DRG.NO.4-97-288-91646/01SHEET 6 OF 71

2091445B

4006 & 4007 VOL D1 TAB-1-32



BCR 590

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158 HNA15 CT 402 TP TEMP. AT SAH - B I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

159 HNA15 CP 402 PP PR. AT AH - B I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

160 HNA30 CT 001 TE TEMP. AT PAH I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

161 HNA30 CT 402 TP TEMP. AT PAH I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

162 HNA30 CP 402 PP PR. AT PAH I/L FLUE GAS 1 -71 -73 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

163 HNA35 CT 001-002 TE TEMP. AT PAH O/L FLUE GAS 2 2400 X 2500 -176 -179 mm WC 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

164 HNA35 CT 401-402 TP TEMP. AT PAH O/L FLUE GAS 2 2400 X 2500 -176 -179 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

165 HNA35 CP 401 PP PR. AT PAH O/L FLUE GAS 1 2400 X 2500 -176 -179 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

166 HNA35 CP 001 PT PR. AT PAH O/L FLUE GAS 1 2400 X 2500 -176 -179 mm WC 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

167 HNA20 CP 001 PT PR. AT SAH-A O/L FLUE GAS 1 -176 -179 mm WC 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

168 HNA20 CT 001-002 TE TEMP. AT SAH-A O/L FLUE GAS 2 -176 -179 mm WC 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

169 HNA20 CP 401 PP PR. AT SAH-A O/L FLUE GAS 1 -176 -179 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

170 HNA20 CT 401-402 TP TEMP. AT SAH-A O/L FLUE GAS 2 -176 -179 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

171 HNA20 CQ 001 AT O2 ANAL AT SAH - A O/L FLUE GAS 1 -176 -179 mm WC 0C 3.54 -- -- -- -- D / I --% BY DRYVOL

% BY DRYVOL

-- --- -- 4-97-288-91552 -- -- E 00

172 HNA25 CP 001 PT PR. AT SAH-A O/L FLUE GAS 1 -176 -179 mm WC 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

173 HNA25 CT 001-002 TE TEMP. AT SAH-A O/L FLUE GAS 2 -176 -179 mm WC 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

174 HNA25 CP 401 PP PR. AT SAH-A O/L FLUE GAS 1 -176 -179 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

175 HNA25 CT 401-402 TP TEMP. AT SAH-A O/L FLUE GAS 2 -176 -179 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

176 HNA25 CQ 001 AT O2 ANAL AT SAH - A O/L FLUE GAS 1 -176 -179 mm WC 0C 3.54 -- -- -- -- D / I --% BY DRYVOL

% BY DRYVOL

-- --- -- 4-97-288-91552 -- -- E 00

177 HNA37 CT 001-002 TE TEMP. AT AH O/L COMMON DUCT FLUE GAS 2 -176 -179 mm WC 0C -- -- -- -- -- D/I,C -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

178 HNA40 CP 401 PP ESP -A -ADD FIELD I/L GATE BLOWER PR. FLUE GAS 1 -- -224 -228 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- 00

179 HNA45 CP 401 PP ESP -B -ADD FIELD I/L GATE BLOWER PR. FLUE GAS 1 -- -224 -228 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- 00

180 HNA50 CP 401 PP ESP -A -ADD FIELD O/L GATE BLOWER PR. FLUE GAS 1 -- -249 -253 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- 00

181 HNA55 CP 401 PP ESP -B -ADD FIELD 0/L GATE BLOWER PR. FLUE GAS 1 -- -249 -253 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- 00

182 HNC10 CP 401 PP ESP -A -EXIST FIELD O/L GATE BLOWER PR. FLUE GAS 1 -- -249 -253 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- 00

183 HNC20 CP 401 PP ESP -B -EXIST FIELD 0/L GATE BLOWER PR. FLUE GAS 1 -- -249 -253 mm WC 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- 00

184 HNC10 CT 001 TE TEMP. AT IDF-A I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

185 HNC10 CP 001 PT PR. AT IDF-A I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

186 HNC10 CP 402 PP PR. AT IDF-A I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

187 HNC10 CT 401 TP TEMP. AT IDF-A I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- -- 00

188 HNC20 CT 001 TE TEMP. AT IDF-B I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- D/I -- 0C 0C -- -- -- 4-97-288-91551 -- -- E 00

DRG.NO.4-97-288-91646/01SHEET 7 OF 71

2091445B

4006 & 4007 VOL D1 TAB-1-33



BCR 590

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35SL

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189 HNC20 CP 001 PT PR. AT IDF-B I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

190 HNC20 CP 402 PP PR. AT IDF-B I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

191 HNC20 CT 401 TP TEMP. AT IDF-B I/L FLUE GAS 1 3250 X2520 -329 -336 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- -- 00

192 HNC10 CT 002 TE TEMP. AT IDF - A MTR-A NDE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

193 HNC10 CT 501 TI TEMP. AT IDF MTR-A NDE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

194 HNC10 CT 003-014 TE TEMP. AT IDF - A MTR-A WNDG METAL 12 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- --- -- -- R 00

195 HNC10 CT 015 TE TEMP. AT IDF-A MTR-A DE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

196 HNC10 CT 502 TI TEMP. AT IDF-A MTR-A DE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

197 HNC10 CT 016 TE TEMP. AT IDF-A DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

198 HNC10 CT 503 TI TEMP. AT IDF-A DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

199 HNC10 CT 017 TE TEMP. AT IDF-A NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

200 HNC10 CT 504 TI TEMP. AT IDF-A NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

201 HNC20 CT 002 TE TEMP. AT IDF - A MTR-A NDE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

202 HNC20 CT 501 TI TEMP. AT IDF MTR-A NDE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

203 HNC20 CT 003-014 TE TEMP. AT IDF - A MTR-A WNDG METAL 12 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+1

00C 0C -- -- -- --- -- -- R 00

204 HNC20 CT 015 TE TEMP. AT IDF-A MTR-A DE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N T=T+5/T+10

0C 0C -- -- -- --- -- -- R 00

205 HNC20 CT 502 TI TEMP. AT IDF-A MTR-A DE METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

206 HNC20 CT 016 TE TEMP. AT IDF-A DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

207 HNC20 CT 503 TI TEMP. AT IDF-A DE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

208 HNC20 CT 017 TE TEMP. AT IDF-A NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- D/I,A, N 77 / 82 0C 0C -- -- -- --- -- -- R 00

209 HNC20 CT 504 TI TEMP. AT IDF-A NDE BRG. METAL 1 -- -- -- -- T -- 0C -- -- -- -- -- L/ I -- 0C -- -- -- -- --- -- -- R 00

210 HNC10 CT 402 TP TEMP. AT IDF-A O/L FLUE GAS 1 -- 25 26 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

211 HNC10 CQ 401 AP ANAL TEST PKT AT IDF-A O/L FLUE GAS 1 -- 25 26 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91552 -- -- - 00

212 HNC10 CP 002 PT PR. AT IDF-A O/L FLUE GAS 1 2520 X 3250 25 26 mm WC 138 150 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

213 HNC10 CP 405 PP PR. AT IDF-A O/L GATE BLOWER FLUE GAS 1 -- 25 26 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

214 HNC20 CT 402 TP TEMP. AT IDF-A O/L FLUE GAS 1 2520 X 3250 25 26 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91551 -- -- - 00

215 HNC20 CQ 401 AP ANAL TEST PKT AT IDF-A O/L FLUE GAS 1 2520 X 3250 25 26 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91552 -- -- - 00

216 HNC20 CP 002 PT PR. AT IDF-A O/L FLUE GAS 1 2520 X 3250 25 26 mm WC 138 150 0C -- -- -- -- -- D/I -- mmWC mmWC -- 4-97-288-91550 -- -- E 00

217 HNC20 CP 405 PP PR. AT IDF-A O/L GATE BLOWER FLUE GAS 1 -- 25 26 mm WC 138 150 0C -- -- -- -- -- T -- -- -- -- -- -- 4-97-288-91550 -- -- -- 00

218 HNC10 CQ 001 AT DUST MONITOR AT IDF-A O/L FLUE GAS 1 2520 X 3250 25 26 mm WC 138 150 0C 22 -- -- -- -- D / I -- PPM PPM -- 4-97-288-91552 -- -- E 00

219 HNC10 CQ 002-004 AT SOX/NOX/CO ANAL AT IDF-A O/L FLUE GAS 3 2520 X 3250 25 26 mm WC 138 150 0C 22 -- -- -- -- D / I -- PPM PPM -- 4-97-288-91552 -- -- E 00

220 HNC20 CQ 001 AT DUST MONITOR AT IDF-B O/L FLUE GAS 1 2520 X 3250 25 26 mm WC 138 150 0C 600/405 -- -- -- -- D / I -- mg/Nm3 ppm -- 4-97-288-91552 -- -- E 00

DRG.NO.4-97-288-91646/01SHEET 8 OF 71

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Write up on boiler auto controls PAGE 1 OF 6

PROJECT: BHATINDA-R&M 2 X 120 MW, CUST. NO: 4006 & 4007 - UNIT - 3 & 4.

RECOMMENDED WRITE-UP ON BOILER AUTO CONTROL SYSTEMS

THE FOLLOWING CONTROL LOOP DESCRIPTIONS ARE COVERED IN THIS WRITE UP.

Sl.No

Description Dwg No.

01 FEEDWATER CONTROL[DRUM LEVEL CONTROL] 4-97-096-91707

02 COMBUSTION CONTROL 4-97-096-91708

03 FUEL FLOW CONTROL 4-97-096-91709

04 AIR FLOW CONTROL 4-97-096-91710

05 FURNACE DRAFT CONTROL 4-97-096-91711

06 PRIMARY AIR HEADER PRESSURE CONTROL 4-97-096-91712

07 MILL OUTLET TEMPERATURE & MILL AIRFLOW CONTROL

4-97-096-91713

08 SUPERHEATER AND REHEATER STEAM TEMPERATURE CONTROL-1 & 2

4-97-096-91714 4-97-096-91715

09 AIR HEATER COLD TEMP. CONTROL (SCAPH CONTROL)

4-97-096-91716

10 HOPCV & HOTCV CONTROLS [PUMP HOUSE]

4-97-096-91717

11 LOFCV, HOTCV & ASPRV CONTROLS [BOILER FRONT]

4-97-096-91718

12 AIRHEATER OUTLET TEMPERATURE CONTROL 4-97-096-91719 BCR NO: 503 INTERNAL CIRCUALTION ONLY

PREPARED

Deva Kumar P

08.09.07 Rev

CHECKED

R.Priya Kala 08.09.07

APPROVED

E.S.Salai Kuberan

08.09.07

00

Bharat Heavy Electricals Limited High Pressure Boiler Plant, Tiruchirapalli- 620 014

Controls & Instrumentation / FB

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4006 & 4007 VOL D1 TAB-1-35

Bharat Heavy Electricals Limited Project: Bhatinda-R&M, Units# 3& 4, 2x 120 MW High Pressure Boiler Plant, Tiruchirapalli- 620 014 Controls & Instrumentation / FB

Write up on boiler auto controls

PAGE 2 OF 6 4 – 97 – 096 – 91704 / 00

01. FEED WATER CONTROL (DRUM LEVEL CONTROL)

The objective of this control system is to maintain the drum level to the normal water level of the drum at all loads. At lower loads (less than 30% MCR), the start up feed control valve will be used and at higher loads Main full load feed control valve is used as final control element. If the Main full load feed control valve is taken for maintenance, standby feed control valve will be used.

Drum level is measured by three transmitters on left and right side respectively through temperature compensated constant head unit. The pressure compensated drum level signal may be selected by “Mid value Auto Selection” circuit for control.

Low load: The drum level measured signal is compared with the drum level set point. The error signal will have a proportional, integral and differential action in the single element controller. This controller output will be the position demand signal for the start up feed control valve. Auto/manual switching facility in DCS is provided for auto/manual selection and operation. Position indication shall be provided for the start up feed control valve in DCS.

High load: At higher loads the start up control valve shall be closed. The steam flow shall be measured. In order to prevent sudden response due to drum swell and shrink on load change, a time lag unit shall be included in the steam flow signal. The temperature compensated feed water flow signal is computed by adding feed water flow at economizer inlet and super heater spray water flow. The error signal produced between drum level measured signal and drum level set point shall have proportional, integral and differential action in the three-element drum level control-ler. This will be added with steam flow signal, which is the feed water flow demand signal (set point for feed water flow). This will be compared with the feed water flow in the feed water controller. Deviation if any will have a proportional and integral action in the feed water controller. This controller output will be the position demand signal for the full load control valve. Auto/manual switching facility in DCS is provided for auto/manual selection and operation. Position indicator shall be provided in DCS for the motor driven BFP hydraulic coupling scoop position indication.

NOTE: - Applicability of feed water DP control for Boiler Feed Control Valve has to be decided by EDN in consultation with PSEB.

02. COMBUSTION CONTROL

The objective of this control is to maintain the turbine throttle pressure constant at the desired value by adjusting the firing rate (both fuel flow and airflow). Turbine throttle pressure may be measured with three transmitters. “Mid value Auto Selection” of the three transmitter shall be selected for control. The selected signal is compared with the set point and any error will have proportional and integral action. A proportional value of total steam flow and derivative of drum pressure signal are taken as feed forward feature for the control. An auto/manual switching facility in DCS is provided. The output of a/m switching facility is the airflow demand and fuel flow demand signal. Refer the 'Notes' in the control scheme for interlocks.

03.FUEL FLOW CONTROL

Fuel flow demand from combustion control and air flow signal from air flow control corrected for fuel air ratio are compared and the lower is selected for the set point of the fuel flow controller (lead-lag system). This is to ensure that under any circumstance the fuel flow should be lesser than the airflow.

Fuel flow is measured by adding the feed signal of the feeders (or mills) in service and the light oil flow corrected for calorific value. The feeder speed/rate measured signal is hooked up to the control after a delay to suit the process lag. The actual fuel flow signal is compared with the developed set point signal above and any deviation will have proportional and integral action. The controller's output signal is the position demand signal for feeder speed regulating device. Bias facility is to be provided in DCS to modify the signal whenever required. An auto/manual switching facility in DCS is provided for each feeder.

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PAGE 3 OF 6 4 – 97 – 096 – 91704 / 00

To ensure air rich furnace at all times, a maximum deviation limit system (MDL) is used. I.e. whenever the fuel flow is more than the airflow this will automatically reduce the fuel flow and increase airflow to a safe value and both the airflow and fuel flow control is transferred to manual.

04. AIR FLOW CONTROL

The secondary airflow is measured at left and right side of the secondary air ducts to wind box by means of aerofoils. Each flow will have temperature compensation. The flow is linearised by means of square root extractors. The total PA flow measured for each mill in service is added to obtain total airflow to the boiler. This signal is compared with the developed set point. The airflow demand from combustion control and actual fuel flow whichever is high (lead lag system) is selected to ensure enriched combustion air. The oxygen in the flue gas at the inlet of AH is measured as primary or redundant. Transfer switch can be selected for either average value or individual value. This signal is compared with excess air set point and any error will have proportional and integral action to have better combustion efficiency. High/low limiters are used to limit the value in case the oxygen analyzer is out of service. Under any circumstance the airflow should not be less than 30% MCR flow. This signal is the developed set point and the airflow signals will have proportional and integral action in the airflow controller.

This position demand signal will be selected to the corresponding FD fans in service through' auto/manual switching facility provided in DCS. To have equal loading of FD fans the FD fan motors current is measured. The difference is used for taking corrective action. The corrected signal is used to position the FD fan-regulating damper. Necessary interlock from FSSS, Boiler auxiliaries interlock system Maximum Deviation Limit (MDL) etc. is provided. Separate auto/manual-switching facility in DCS and position indicator for each FD fan-regulating devices are provided.

05. FURNACE DRAFT CONTROL

The main objective of the control is to maintain the furnace pressure constant at the desired set value at all loads. This is achieved by changing the flow of flue gas by modulating the inlet damper and varying Three transmitters measure furnace pressure. One signal is selected by mid value auto selection circuit for control. Excessive furnace pressure is monitored for directional block on Induced Draft (ID) and Forced Draft (FD) fans. Furnace pressure is compared with set point and error, will have proportional and integral action. Fuel demand signal is added as a feed forward feature. Master Fuel Trip (MFT) feed forward feature is provided to minimize negative furnace pressure excursion. Separate auto/manual-switching facility and the position indicator in DCS for each ID fan regulating devices are provided.

To have equal loading of the ID fans each ID fan motor current (sum of channel 1 and channel 2 current) is measured averaged and compared. The difference is used for taking corrective action. The corrected signal is used to position the ID fan inlet damper. The ID fan inlet damper positions between a maximum and a minimum position limit for optimized control action. If ID fan position goes outside these limits, an error signal goes to a controller, whose output is used to vary fan speed to bring back the inlet damper within the set limits.

06. PRIMARY AIR HEADER PRESSURE CONTROL

The main objective of this control is to adjust the primary air header pressure according to the feeder speed. That is, out of all the feeders, the feeder speed, which is higher than that of others is considered as set value for this control.

Primary air header pressure is measured with three transmitters. One signal is selected by mid value auto selection circuit for control. The measured signal is compared with the selected feeder speed signal

Through a high signal selector to maintain the minimum header pressure. Deviation if any will have proportional and integral action. Separate auto/manual-switching facility and position indicator is provided for each Primary Air (PA) fan-regulating device in DCS.To have equal loading of two running PA fans, the PA fans motor current is measured, averaged and compared. The difference is used for taking corrective action. The corrective signal is used to position the PA fan-regulating unit.

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4006 & 4007 VOL D1 TAB-1-37



PAGE 4 OF 6 4 – 97 – 096 – 91704 / 00

07. MILL OUTLET TEMPERATURE AND MILL AIRFLOW CONTROL

The objective of this control system is to adjust the mill airflow according to the feeder speed and to maintain the mill outlet temperature at the constant set value.

Mill airflow is maintained by adjusting the hot air regulating damper while the mill outlet temperature is maintained constant by adjusting the cold air-regulating damper. The temperature compensated mill airflow is linearised by the square root extractor. This airflow signal is compared with variable airflow set point as a function of feeder speed. Any error between these two signals will have proportional plus integral action. Rate of change of fuel demand signal is added to provide feed forward feature. An auto/manual switching facility in DCS with position indicator is provided.

The mill outlet temperature is compared with constant set point and error will have proportional, integral and derivative action. An auto/manual switching facility in DCS with position indicator is provided.

08. SUPER HEATER/REHEATER STEAM TEMPERATURE CONTROL

General

Steam temperature control is provided by a combination of burner nozzle tilt positioning and Super-heater (SH), Re-heater (RH) de-superheating spray. Steam temperature is maintained by allowing nozzle tilt to respond to the lower of either SH or RH outlet temperature, with spray responding to the higher. Auto manual switching facility in DCS is to be provided for modulating the following

1 SH spray water control valve

2 RH spray water control valve – left

3 RH spray water control valve - right

4 Burner tilt power cylinder.

The Temperature measurement is selected by mid valve Auto selection (MVAS) control circuit.

SH spray water valve control

In the automatic mode, each SH spray water valve is controlled by a cascade control. Under normal conditions SH outlet temperature (Tsho), the primary controlled variable, is in the outer loop of the cascade control for valve; SH De-super heater (DESH) outlet temperature (Tshdso), an index of the immediate effect of spray valve operation, is in the inner loop. The outer loop PID controller receives an error signal equal to the deviation of Tsho set point and measured final SH outlet temperature (Tshol and Tshor). The Tsho set point is programmed as a function of unit steam flow for constant pressure operation. The outer loop controller establishes a set point for the SH DESH outlet temp. This set point is compared to measured Tshdso and the resulting error is used to position the SH spray valve control.

These feed forwards are needed to compensate for over firing and under firing which may be required initially. When changing unit load, feed forward signals are utilized as follows (using unit load increase as an example):

1. The rate of change of fuel demand increase (an indication of over firing) is used to open the SH spray valves to counter the initial temperature rise.

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PAGE 5 OF 6 4 – 97 – 096 – 91704 / 00

2. Drum pressure and steam flow (applied inversely) to spray valve demand) and tilt position (applied directly) are used as an index to recognize the tendency for temp. To drop after item-1 above occurs, and is used to close the SH spray valves to counter the subsequent temperature drop.

Interlocks are provided to close the SH spray valves at loads less than 20% MCR.

RH spray water valve control

In the automatic mode, each RH DESH spray water valve is controlled by a cascade control. Under normal operating conditions RH outlet temperature (Trho), the primary controlled variable is in the outer loop of each cascade control; RH DESH outlet temperature (Trhdso), an index of the immediate effect of spray valve operation, is in the inner loop.

The outer loop PID controller receives an error signal final RH outlet temperature (Trhol and Trhor). The Trho set point is programmed against the main steam flow curve, for constant pressure operation. The outer loop controller output is modified with tilt position to establish a set point for the RH DESH outlet temperature. This set point is compared to measure Trhdso, and the resulting error is used to position the associated RH DESH spray water valve.

Interlocks are provided to keep the spray valves closed at loads less than 20% MCR.

Nozzle tilt control

The average Tsho and Trho error signals are compared and the greater of the two errors (i.e., the lower of the two temperatures) is selected for nozzle tilt control. An interlock is provided to keep the tilts at their base (horizontal) position at loads less than 25% MCR. If any spray water valve opens fully, the tilt control is interlocked to disallow further raising of the tilts, and thus prevent possible over heating of the SH and RH outlet lead.

Refer notes in control scheme for interlocks.

09. AIR HEATER COLD END TEMPERATURE CONTROL [SCAPH]

The purpose of this control loop is to maintain the cold end temperature above the dew point thus preventing condensation and resultant corrosion of air-heater surfaces. The cold end temperature of AH. I.e. Sec Air Temp at APH inlet and Flue gas Temp at Air PH outlet is measured using 3 TE’s placed at APH inlet and Outlet respectively is measured and averaged. The average temperature is compared with the set point and any deviation will have proportional and integral action. An auto/manual switching facility in DCS with position indicator is provided. The operation of this control may be required while lighting up and low load operation of the boiler.

10. HEAVY OIL PRESSURE CONTROL – PER BOILER

Heavy oil flow is regulated by maintaining the pressure at pump outlet. Two pressure transmitters are used to measure the pressure and the healthy signal is applied to the controller where it is compared with the set point. The error signal will have proportional & integral action in the controller. The controller output is the position demand signal for pressure control valve of heavy oil.

10.1 HEAVY FUEL OIL TEMPERATURE CONTROL – PER BOILER

The purpose of the control is to maintain HFO temperature. The HFO is heated with the help of steam. The temperature after heater set is measured into primary and redundant transmitters. Deviation is alarmed and the controller is tripped to manual. The selected signal is compared with the set point. The error will have proportional and integral action. The controller output will be the position demand signal for the temperature control valve located

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4006 & 4007 VOL D1 TAB-1-39



PAGE 6 OF 6 4 – 97 – 096 – 91704 / 00

in the fuel oil line. Auto/manual station is provided for auto/manual selection for operation. Position indication is provided for the heavy fuel oil temperature control valve.

11. LIGHT OIL FLOW CONTROL [BOILER FRONT]

Light oil flow is regulated by maintaining the pressure at pump outlet. Two pressure transmitters are used to measure the pressure and the healthy signal is applied to the controller where it is compared with the set point. The error signal will have proportional & integral action in the controller. The controller output is the position demand signal for pressure control valve of light oil.

11.1. HEAVY FUEL OIL FLOW CONTROL [BOILER FRONT]

The purpose of the control system is to maintain the required HFO flow by maintaining constant pressure in the header. The pressure after flow control valve is measured with primary and redundant transmitters. Deviation is alarmed and the controller is tripped to manual. The selected signal is compared with the set point. The error will have proportional and integral action. The controller output will be the position demand signal for the flow control valve located in the fuel oil line. Auto/manual station is provided for auto/manual selection for operation. Position indication is provided for the heavy fuel oil flow control valve.

11.2. ATOMISING STEAM PRESSURE CONTROL [BOILER FRONT]

The purpose of the control system is to maintain the pressure of atomizing steam line at the required value. The atomizing steam pressure is measured with primary and redundant transmitters. Deviation is alarmed and the controller is tripped to manual. The selected signal is compared with the set point. The error will have proportional and integral action. The controller output will be the position demand signal for the atomizing pressure control valve. Auto/manual station is provided for auto/manual selection. Position indication is provided for the atomizing pressure control valve.

12. AH OUTLET TEMPERATURE CONTROL (HOT GAS DAMPER CONTROL)

This loop is used to equalise primary and secondary airheater gas outlet temperatures. This serves to reduce gas temperature imbalances (stratification) at ID fan and increases unit efficiency. In the automatic mode , average primary and secondary airheater gas outlet temperatures are compared and the resulting signal is received by a PI controller. The controller output is received by two function generators, whose output determine damper position. A limit is provided to maintain damper operator between a specified minimum and full open position. An alarm is activated if dampers reach their minimum position. When a temperature difference is sensed, the controller output will change and the damper controlling the hotter gas outlet will begin to close while the damper controlling the colder gas outlet remain open. (see function generator on the reference drawing) the resultant redistribution of hot gas will serve to equalise the outlet temperatures. With this scheme one damper (that controlling the colder outlet) will always fully open while the other damper modulates between its minimum and full open position. In manual control, dampers are to be initialised by the operator at 100 % open position. A signal indicating that both dampers are fully open is to be interlocked into the ID fan start logic as a start permissive. Transfers are designed to be bumpless. If control power supply is lost dampers are to lock in position or to be forced fully open.

Refer notes in auto control scheme for interlocks & final control elements.

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4006 & 4007 VOL D1 TAB-1-46

2091445B

4006 & 4007 VOL D1 TAB-1-47

2091445B

4006 & 4007 VOL D1 TAB-1-48

2091445B

4006 & 4007 VOL D1 TAB-1-49

2091445B

4006 & 4007 VOL D1 TAB-1-50

2091445B

4006 & 4007 VOL D1 TAB-1-51

2091445B

4006 & 4007 VOL D1 TAB-1-52

2091445B

4006 & 4007 VOL D1 TAB-1-53

2091445B

4006 & 4007 VOL D1 TAB-1-54

2091445B

4006 & 4007 VOL D1 TAB-1-55

2091445B

4006 & 4007 VOL D1 TAB-1-56

2091445B

4006 & 4007 VOL D1 TAB-1-57

PROJECT-Gurunanak TPS [Bhatinda R&M]CAPACITY- 2 X 120 MW.UNITS # 3 &4CUSTOMER : Punjab State Electricity Board.CUST NO. 4006&4007

Drg. no: 4-97-599-91584/02

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1 HLB 10 AA 101 FD FAN A BLADE PITCH CONTROL 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR FD FAN-A BET S19 & S20

CI-FB/ TRICHY 02 AIR FLOW CONTROL

2 HLB 20 AA 101 FD FAN B BLADE PITCH CONTROL 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR FD FAN-B BET S22 & S23

CI-FB/ TRICHY 02 AIR FLOW CONTROL

3 HLA 10 AA 001 FD FAN A OUTLET DAMPER 01 U 01 E O/C --- --- --- --- --- DDCMIS --- NEAR FD FAN-A BET S19 & S20

E, C&I/Ranipet. 02

4 HLA 20 AA 001 FD FAN B OUTLET DAMPER 01 U 01 E O/C --- --- --- --- --- DDCMIS --- NEAR FD FAN-B BET S22 & S23

E, C&I/Ranipet. 02

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5 HLA 10 AA 002 SCAPH A BYPASS DAMPER 01 U 01 E INCH --- --- --- --- --- DDCMIS Y EL 9000 BET S19 & S20 E, C&I/Ranipet. 02 REMOTE MANUAL

6 HLA 20 AA 002 SCAPH B BYPASS DAMPER 01 U 01 E INCH --- --- --- --- --- DDCMIS Y EL 9000 BET S22 & S23 E, C&I/Ranipet. 02 REMOTE MANUAL

7 HLA 11 AA 001 SCAPH A INLET DAMPER 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 9000 BET S19 & S20 E, C&I/Ranipet. 02

8 HLA 21 AA 001 SCAPH B INLET DAMPER 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 9000 BET S22 & S23 E, C&I/Ranipet. 02

9 HLA 11 AA 002 SCAPH A OUTLET DAMPER 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 9000 BET S19 & S20 E, C&I/Ranipet. 02

10 HLA 21 AA 002 SCAPH B OUTLET DAMPER 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 9000 BET S22 & S23 E, C&I/Ranipet. 02

11 HLA 10 AA 003 AIR HEATER - A INLET DAMPER - SEC. AIR E, C&I/Ranipet. 01

12 HLA 20 AA 003 AIR HEATER - B INLET DAMPER - SEC. AIR E, C&I/Ranipet. 01

13 HHL 11,12,13,14AA 501

WIND BOX SEC.AIR DAMPER ELEVATION AA 04 U -- M O/C --- --- --- --- --- -- --- EL 13600 FS/ TRICHY 02

14HHL 11,12,13,14AA111,112,113,114

WIND BOX SEC.AIR DAMPER ELEVATION AB,BC,CD,DD 16 U 01 P REG AO SP FC E N SADC N

AB - EL 14802BC - EL 16152CD - EL 17552DD - EL 18717

FS/ TRICHY 02 SEC AIR DAMPER CONTROL

15 HHL 11,12,13,14AA 115,116

WIND BOX OFA DAMPER ELEVATION OFA-UPPER & LOWER 08 U 01 P REG AO SP FC E N SADC N OFA- L- EL 18967

OFA-U -EL 19217FS/ TRICHY 02 SEC AIR DAMPER

CONTROL

Deleted

Deleted

SHEET NO: 1 OF 6

2091445B

4006 & 4007 VOL D1 TAB-1-58


Drg. no: 4-97-599-91584/02

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16HHL 11,12,13,14AA 101, 102, 103, 104,

WIND BOX SEC.AIR DAMPER ELEVATION D TO A 16 U 01 P REG AO SP FC E N SADC N

A- EL 14187B- EL 15477C- EL 16777D- EL 18237

FS/ TRICHY 02SEC AIR DAMPER CONTROL

17 HBK 11,12,13,14AA 101 BTPS 04 U 01 P REG AO SP FC E --- DDCMIS Y FS/ TRICHY 02 REHEATER TEMP

CONTROL

18 HHQ 11 AA 001 SCANNER AIR EMERGENCY DAMPER 01 U 01 P O/C --- --- - Y FSSS --- EL 13500 NR S16 FS/ TRICHY 02

19 HHQ 20AA 501&502 SCANNER AIR FAN INLET DAMPER 02 U -- M O/C --- --- --- --- --- -- --- EL 13500 NR S16 FS/ TRICHY 02

20 HHQ 40 AA 001 SCANNER AIR AUTO TRANSFER DAMPER 01 U -- A O/C --- --- --- --- --- -- --- EL 13500 NR S16 FS/ TRICHY 02

21 HFE 10 AA 101 PRIMARY AIR FAN A BLADE PITCH CONTROL DAMPER 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR PA FAN-A BET

FH1&FH2CI-FB/ TRICHY 02

PRY AIR HEADER PRESSURE CONTROL

22 HFE 20 AA 101 PRIMARY AIR FAN B BLADE PITCH CONTROL DAMPER 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR PA FAN-B BET

FH2&FH3CI-FB/ TRICHY 02

PRY AIR HEADER PRESSURE CONTROL

23 HFE 10 AA 001 PRIMARY AIR FAN A OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- NEAR PA FAN-A BET FH1&FH2

E, C&I/Ranipet. 02

24 HFE 20 AA 001 PRIMARY AIR FAN B OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- NEAR PA FAN-B BET FH2&FH3

E, C&I/Ranipet. 02

25 HFE 51 AA 501 COLD PRIMARY AIR GATE A 01 U -- M O/C --- --- --- --- --- --- --- NEAR DS1 (MILL A) E, C&I/Ranipet. 02

26 HFE 52 AA 501 COLD PRIMARY AIR GATE B 01 U -- M O/C --- --- --- --- --- --- --- NR S5 (MILL B) E, C&I/Ranipet. 02

27 HFE 53 AA 501 COLD PRIMARY AIR GATE C 01 U -- M O/C --- --- --- --- --- --- --- NR S1R (MILL C) E, C&I/Ranipet. 02

28 HFE 54 AA 501 COLD PRIMARY AIR GATE D 01 U -- M O/C --- --- --- --- --- --- --- NEAR DS3 (MILL D) E, C&I/Ranipet. 02

29 HFE 51 AA 101 COLD PRIMARY AIR DAMPER A 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR DS1 (MILL A) CI-FB/ TRICHY 02 MILL TEMP CONTROL

30 HFE 52 AA 101 COLD PRIMARY AIR DAMPER B 01 U 01 P REG AO SP FC E N DDCMIS Y NR S5 (MILL B) CI-FB/ TRICHY 02 MILL TEMP CONTROL

31 HFE 53 AA 101 COLD PRIMARY AIR DAMPER C 01 U 01 P REG AO SP FC E N DDCMIS Y NR S1R (MILL C) CI-FB/ TRICHY 02 MILL TEMP CONTROL

32 HFE 54 AA 101 COLD PRIMARY AIR DAMPER D 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR DS3 (MILL D) CI-FB/ TRICHY 02 MILL TEMP CONTROL

33 HFE 61 AA 201 HOT PRIMARY AIR GATE A 01 U 01 P O/C --- --- --- Y FSSS --- NEAR DS1 (MILL A) E, C&I/Ranipet. 02

SHEET NO: 2 OF 6

2091445B

4006 & 4007 VOL D1 TAB-1-59


Drg. no: 4-97-599-91584/02

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34 HFE 62 AA 201 HOT PRIMARY AIR GATE B 01 U 01 P O/C --- --- --- Y FSSS --- NR S5 (MILL B) E, C&I/Ranipet. 02

35 HFE 63 AA 201 HOT PRIMARY AIR GATE C 01 U 01 P O/C --- --- --- Y FSSS --- NR S1R (MILL C) E, C&I/Ranipet. 02

36 HFE 64 AA 201 HOT PRIMARY AIR GATE D 01 U 01 P O/C --- --- --- Y FSSS --- NEAR DS3 (MILL D) E, C&I/Ranipet. 02

37 HFE 61 AA 101 HOT PRIMARY AIR DAMPER A 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR DS1 (MILL A) CI-FB/ TRICHY 02 MILL AIR FLOW CONTROL

38 HFE 62 AA 101 HOT PRIMARY AIR DAMPER B 01 U 01 P REG AO SP FC E N DDCMIS Y NR S5 (MILL B) CI-FB/ TRICHY 02 MILL AIR FLOW CONTROL

39 HFE 63 AA 101 HOT PRIMARY AIR DAMPER C 01 U 01 P REG AO SP FC E N DDCMIS Y NR S1R (MILL C) CI-FB/ TRICHY 02 MILL AIR FLOW CONTROL( ) CONTROL

40 HFE 64 AA 101 HOT PRIMARY AIR DAMPER D 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR DS3 (MILL D) CI-FB/ TRICHY 02 MILL AIR FLOW CONTROL

41 HFW 10 AA 101 DYNAVANE FILTER BLEED AIR DAMPER 01 U 01 P REG --- --- --- --- --- -- --- MILL BAY C&D BET S13 &S 9

FS/ TRICHY 02 LOCAL PNUEMATIC CONTROLLER

42 HFW 11,12AA 501 SEAL AIR FAN INLET DAMPER 02 U -- M O/C --- --- --- --- --- -- --- MILL BAY C&D BET S13 &S

9FS/ TRICHY 02

43 HFW 20 AA 201 SEAL AIR AUTO TRANSFER DAMPER 01 U -- A O/C --- --- - --- --- -- --- MILL BAY C&D BET S13 &S 9

FS/ TRICHY 02

44 HFW 21 AA 201 SEAL AIR TO MILL A DAMPER 01 U 01 P O/C --- --- --- Y FSSS --- NEAR DS1 (MILL A) FS/ TRICHY 02

45 HFW 22 AA 201 SEAL AIR TO MILL B DAMPER 01 U 01 P O/C --- --- --- Y FSSS --- NR S5 (MILL B) FS/ TRICHY 02

46 HFW 23 AA 201 SEAL AIR TO MILL C DAMPER 01 U 01 P O/C --- --- --- Y FSSS --- NR S1R (MILL C) FS/ TRICHY 02

47 HFW 24 AA 201 SEAL AIR TO MILL D DAMPER 01 U 01 P O/C --- --- --- Y FSSS --- NEAR DS3 (MILL D) FS/ TRICHY 02

48 HFW 31 AA 501 SEAL AIR TO COAL FEEDER A 01 U -- M O/C --- --- --- --- --- -- --- EL 13200 NR FEEDER A FS/ TRICHY 02

49 HFW 32 AA 501 SEAL AIR TO COAL FEEDER B 01 U -- M O/C --- --- --- --- --- -- --- EL 13200 NR FEEDER B FS/ TRICHY 02

50 HFW 33 AA 501 SEAL AIR TO COAL FEEDER C 01 U -- M O/C --- --- --- --- --- -- --- EL 13200 NR FEEDER C FS/ TRICHY 02

51 HFW 34 AA 501 SEAL AIR TO COAL FEEDER D 01 U -- M O/C --- --- --- --- --- -- --- EL 13200 NR FEEDER D FS/ TRICHY 02

52 HFE 31 AA 201 SEAL AIR TO MILL A COAL PIPE 01 U 01 P O/C --- --- --- Y FSSS --- NEAR DS1 (MILL A) Mill Engg., Hyd 02

53 HFE 32 AA 201 SEAL AIR TO MILL B COAL PIPE 01 U 01 P O/C --- --- --- Y FSSS --- NR S5 (MILL B) Mill Engg., Hyd 02

54 HFE 33 AA 201 SEAL AIR TO MILL C COAL PIPE 01 U 01 P O/C --- --- --- Y FSSS --- NR S1R (MILL C) Mill Engg., Hyd 02

SHEET NO: 3 OF 6

2091445B

4006 & 4007 VOL D1 TAB-1-60


Drg. no: 4-97-599-91584/02

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55 HFE 34 AA 201 SEAL AIR TO MILL D COAL PIPE 01 U 01 P O/C --- --- --- Y FSSS --- NEAR DS3 (MILL D) Mill Engg., Hyd 02

56 HFE 61 AA 202 - 205 MILL A DISCHARGE DAMPER 04 U 01 P O/C --- --- --- Y FSSS --- NEAR DS1 (MILL A) Mill Engg., Hyd 02

57 HFE 62AA 202 - 205 MILL B DISCHARGE DAMPER 04 U 01 P O/C --- --- --- Y FSSS --- NR S5 (MILL B) Mill Engg., Hyd 02

58 HFE 63AA 202 - 205 MILL C DISCHARGE DAMPER 04 U 01 P O/C --- --- --- Y FSSS --- NR S1R (MILL C) Mill Engg., Hyd 02

59 HFE 64AA 202 - 205 MILL D DISCHARGE DAMPER 04 U 01 P O/C --- --- --- Y FSSS --- NEAR DS3 (MILL D) Mill Engg., Hyd 02

60 HFE 61AA 501-504 COAL BURNER INLET GATE (MILL-A) 04 U -- M O/C --- --- --- --- --- -- ---

A- EL 14187 NR S1L - CORNER1A- EL 14187 NR S3L - CORNER2A- EL 14187 NR S3R - CORNER3A- EL 14187 NR S1R- CORNER4

FS/ TRICHY 02

61 HFE 62AA 501-504 COAL BURNER INLET GATE (MILL-B) 04 U -- M O/C --- --- --- --- --- -- ---

B- EL 15477 NR S1L - CORNER1B- EL 15477 NR S3L - CORNER2B- EL 15477 NR S3R - CORNER3B- EL 15477 NR S1R- CORNER4

FS/ TRICHY 02

62 HFE 63AA 501-504 COAL BURNER INLET GATE (MILL-C) 04 U -- M O/C --- --- --- --- --- -- ---

C- EL 16777NR S1L - CORNER1C- EL 16777NR S3L - CORNER2C- EL 16777NR S3R - CORNER3C- EL 16777NR S1R- CORNER4

FS/ TRICHY 02

SHEET NO: 4 OF 6

2091445B

4006 & 4007 VOL D1 TAB-1-61


Drg. no: 4-97-599-91584/02

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63 HFE 64AA 501-504 COAL BURNER INLET GATE (MILL-D) 04 U -- M O/C --- --- --- --- --- -- ---

D- EL 18237NR S1L - CORNER1D- EL 18237NR S3L - CORNER2D- EL 18237NR S3R - CORNER3D- EL 18237NR S1R- CORNER4

FS/ TRICHY 02

64 HFB 01 AA 501 BUNKER A OUTLET GATE 01 U -- M O/C --- --- --- --- --- -- --- EL 14900 BET BAY B&C FS/ TRICHY 02

65 HFB 02 AA 501 BUNKER B OUTLET GATE 01 U -- M O/C --- --- --- --- --- -- --- EL 14900 BET BAY B&C FS/ TRICHY 02

66 HFB 03 AA 501 BUNKER C OUTLET GATE 01 U -- M O/C --- --- --- --- --- -- --- EL 14900 BET BAY B&C FS/ TRICHY 02

67 HFB 04AA 501 BUNKER D OUTLET GATE 01 U -- M O/C --- --- --- --- --- -- --- EL 14900 BET BAY B&C FS/ TRICHY 02

68 HNA 20 AA 001 SEC AIR HEATER A GAS OUTLET DAMPER E, C&I/Ranipet. 01

69 HNA 25 AA 001 SEC AIR HEATER B GAS OUTLET DAMPER E, C&I/Ranipet. 01

Deleted

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SHEET NO: 5 OF 6

2091445B

4006 & 4007 VOL D1 TAB-1-62


Drg. no: 4-97-599-91584/02

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70 HNA 35 AA 001 PRI AIR HEATER GAS OUTLET DAMPER 01 U 01 P REG --- --- --- --- --- DDCMIS --- EL 24600 NR AH3 CI-FB/ TRICHY 02 MODIFIED

71 HNA 40 AA 001 EP A -ADDITIONAL FIELDS- INLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 16670 NR K2 E, C&I/Ranipet. 02

72 HNA 45 AA 001 EP B -ADDITIONAL FIELDS- INLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 16670 NR K4 E, C&I/Ranipet. 02

73 HNA 50 AA 001 EP A -ADDITIONAL FIELDS- OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 16200 BET L1&L2 E, C&I/Ranipet. 02

74 HNA 55 AA 001 EP B - ADDITIONAL FIELDS- OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 16200 BET L3&L4 E, C&I/Ranipet. 02

75 HNC 10 AA 001 EP A - EXISTING FIELD - OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 14150 BET TI&T2 E, C&I/Ranipet. 02

76 HNC 20 AA 001 EP B - EXISTING FIELD - OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 14150 BET T4&T5 E, C&I/Ranipet. 02

77 HNC 10 AA 002 ID FAN A INLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 14150 BET UI&U2 E, C&I/Ranipet. 02

78 HNA 20 AA 002 ID FAN B INLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 14150 BET U4&U5 E, C&I/Ranipet. 02

79 HNC 10 AA 101 ID FAN A INLET DAMPER 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR ID FAN-A BET U1&U2

CI-FB/ TRICHY 02 FURNACE DRAFT CONTROL

80 HNC 20 AA 101 ID FAN B INLET DAMPER 01 U 01 P REG AO SP FC E N DDCMIS Y NEAR ID FAN-A BET U4&U5

CI-FB/ TRICHY 02 FURNACE DRAFT CONTROL

81 HNC 10 AA 003 ID FAN A OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 6200 BET T1&T2 E, C&I/Ranipet. 02

82 HNC 20 AA 003 ID FAN B OUTLET GATE 01 U 01 E O/C --- --- --- --- --- DDCMIS --- EL 6200 BET T4&T5 E, C&I/Ranipet. 02

83 HNA 37 AA 001 SEC AIR HEATER A&B GAS OUTLET DAMPER IN COMMON DUCT

01 U 01 P REG --- --- --- --- --- DDCMIS --- EL 19200 CI-FB/ TRICHY 02 ADDED

SHEET NO: 6 OF 6

2091445B

4006 & 4007 VOL D1 TAB-1-63

2091445B

4006 & 4007 VOL D1 TAB-1-64

Project - GURUNANAK TPS [BHATINDA R&M] ,Capacity - 2 X 120 MW.Unit # 3 &4CUST : Punjab State Electricity boardCUST NO. 4006&4007

SCHEDULE OF LT MOTORS(PRELIMINARY)

BCR : 415

VO

LTA

GE

TYPE

(NO

RM

AL(

N)

/E

ME

RG

EN

CY

(E))

SOU

RC

E

01 FURNACE TEMP. PROBE MOTOR 01 0.37 DDCMIS 415V,3PH,50HZ NLOCALSTARTERBOX

NR TRY N 00

02 SCANNER AIR FAN AC MOTOR 01 3.70 FSSS 415V,3PH,50HZ N LTMCC NR BOP N 00

03 SCANNER AIR FAN DC MOTOR 01 3.70 FSSS 220 V DC ELOCALSTARTERBOX

NR TRY S 00

04 TRANSVERSE MOTORS FOR LRSB 20 0.37 SBCP 415V,3PH,50HZ N SBMCC R TRY N 00

05 ROTARY MOTORS FOR LRSB 20 0.45 SBCP 415V,3PH,50HZ N SBMCC NR TRY N 00

06 TRANSVERSE MOTOR FOR WB 40 0.45 SBCP 415V,3PH,50HZ N SBMCC R TRY N 00

07 ROTARY MOTORS FOR WB 40 0.09 SBCP 415V,3PH,50HZ N SBMCC NR TRY N 00

08 FD FAN A&B LUBE OIL PUMP MOTORS 04 3.70 DDCMIS 415V,3PH,50HZ N LTMCC NR BOP N 00

09 PA FAN A&B LUBE OIL PUMP MOTORS 04 2.20 DDCMIS 415V,3PH,50HZ N LTMCC NR BOP N 00

10 ID FAN O/L DAMPER BLOWER MOTOR 02 1.50 DDCMIS 415V,3PH,50HZ N LTMCC NR BOP N 00

11 SEAL AIR FAN MOTOR 02 37.00 FSSS 415V,3PH,50HZ N LTMCC NR BOP N 00

12 GRAVIMETRIC FEEDER MAIN MOTOR 04 7.50 FSSS 415V,3PH,50HZ N

FEEDERREMOTECONTROLCABINET

NR TRY N 00

13 GRAVIMETRIC FEEDER CLEAN OUT CONVEYOR MOTOR 04 1.50 FEEDER REMOTE

CONTROL CABINET 415V,3PH,50HZ N

FEEDERREMOTECONTROLCABINET

NR TRY N 00

14 SPARE FEEDERS 02 3.70 -- 415V,3PH,50HZ N LTMCC -- BOP N 00

15 SPARE FEEDERS 01 15.00 -- 415V,3PH,50HZ N LTMCC -- BOP N 00

SPE

ED

(RPM

)

STA

RTE

RTY

PE(R

EV

ER

SIB

LE(R

)/N

ON

RE

VE

RSI

BLE

(NR

))

STA

RTE

RSC

OPE

BO

P-B

HE

L[B

HO

PAL]

TRY

-BH

EL[

TRIC

HY

]

POWER SUPPLY

QTY

(NO

)/BLR

RA

TIN

G(K

W)

FLC

(AM

P)

CO

NTR

OLL

ED

FRO

M

RE

MA

RK

S

LOA

D(N

OR

MA

L(N

)/ST

AN

DY

(S))

RE

VIS

ION

SLN

O

DE

SCR

IPTI

ON

DRG NO : 4-97-599-91538 / 00SHEET NO: 2 OF 2

2091445B

4006 & 4007 VOL D1 TAB-1-65

2091445B

4006 & 4007 VOL D1 TAB-1-66


SCHEDULE OF SERVOMOTORS BCR NO: 617

VOLT

AG

E

TYPE

(NO

RM

AL(

N) /

EM

ERG

ENC

Y(E)

SOU

RC

E

1 HAN13AA051 INTERMITTENT BLOW DOWN - REG 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP Y DDCMIS EL 4500 NEAR S1R 02

2 HAN12AA051 DRUM CONTINUIOUS BLOW DOWN - REG 1 K150 0.72 4.40 3.40 415V,3PH,50HZ N V&D LTMCC R N BOP Y DDCMIS EL 13765 NEAR S5 02

3 HAN11AA051 DRUM EMERGENCY DRAIN - REG 1 SA30A32 1.10 5.72 2.90 415V,3PH,50HZ N V&D LTMCC R N BOP Y DDCMIS EL 14000 NEAR S10 02

4 HAN20AA051 SH START UP VENT - REG 1 SA50E90 4.00 26.00 9.00 415V,3PH,50HZ N V&D LTMCC R N BOP Y DDCMIS EL 45300 BET S3L AND S4L 02

5 LBA01AA051 BYPASS FOR MS LINE - REG-LEFT 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP Y DDCMIS EL38750 BET S1L AND S9 02

6 LBA02AA051 BYPASS FOR MS LINE - REG-RIGHT 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP Y DDCMIS EL38750 BET S1R AND S13 02

1 HAC10AA001 ECO INLET-ISOL 1 SA50E90 4.00 26.00 9.00 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL18500 NEAR S3R 02

2 HAC10AA002 INTEGRAL BYPASS FOR ECO INLET -ISOL 1 SA3A16 0.06 0.38 0.29 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL18500 NEAR

S3R 02

3 HAN13AA001 INTERMITTENT BLOW DOWN - ISOL 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL4500 NEAR S1R 02

4 HAC11AA001 ECO RECIRCULATION - ISOL 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL 20327 NEAR S7 02

5 HAN11AA001 DRUM EMERGENCY DRAIN -ISOL 1 SA50AB32 2.20 8.52 4.10 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL 14000 NEAR S10 02

6 HAN20AA001 PSH START UP VENT - ISOL 1 SA50E90 4.00 26.00 9.00 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL 45300 BET S3L AND S4L 02

7 LBA01AA001 MS LINE DRAIN -ISOL [LEFT] 1 K30 0.09 0.90 0.60 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL 35900 NEAR S10 02

8 LBA02AA001 MS LINE DRAIN -ISOL [RIGHT] 1 K30 0.09 0.90 0.60 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL 35900 NEAR S16 02

9 LBA01AA003 MSL - ISOL [LEFT] 1 SMB2-60 4.80 10.40 11.00 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL38750 BET S1L AND S9 02

10 LBA02AA003 MSL - ISOL [RIGHT] 1 SMB2-60 4.80 10.40 11.00 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL38750 BET S1R AND S13 02

11 LBA01AA002 BYPASS FOR MS LINE -ISOL [LEFT] 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL38750 BET S1L AND S9 02

12 LBA02AA002 BYPASS FOR MS LINE -ISOL [RIGHT] 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL38750 BET S1R AND S13 02

LOC

ATI

ON

SL N

O

DES

CR

IPTI

ON

QTY

(NO

)

KK

S TA

G N

O

CO

NTR

OLL

ED F

RO

M

TYPE

OF

SER

VOM

OTO

R

RA

TIN

G (K

W)

FLC

(AM

P)

INCHING VALVES

ISOLATING ON / OFF VALVES

OLR

(AM

P)

POSI

TIO

N T

RA

NSM

ITTE

R.

YE

S(Y)

/ N

O(N

)

REM

AR

KS

STA

RTE

R

TYPE

(REV

ERSI

BLE

(R) /

N

ON

REV

ERSI

BLE

(NR

)

REV

ISIO

N

STA

RTE

R /

FEED

ER S

CO

PEPOWER SUPPLY

INTE

GR

AL

STA

RTE

R Y

/N

DRG NO: 4-97-599-91191 / 02SHEET NO : 2 of 3

2091445B

4006 & 4007 VOL D1 TAB-1-67


SCHEDULE OF SERVOMOTORS BCR NO: 617

VOLT

AG

E

TYPE

(NO

RM

AL(

N) /

EM

ERG

ENC

Y(E)

SOU

RC

E

LOC

ATI

ON

SL N

O

DES

CR

IPTI

ON

QTY

(NO

)

KK

S TA

G N

O

CO

NTR

OLL

ED F

RO

M

TYPE

OF

SER

VOM

OTO

R

RA

TIN

G (K

W)

FLC

(AM

P)

OLR

(AM

P)

POSI

TIO

N T

RA

NSM

ITTE

R.

YE

S(Y)

/ N

O(N

)

REM

AR

KS

STA

RTE

R

TYPE

(REV

ERSI

BLE

(R) /

N

ON

REV

ERSI

BLE

(NR

)

REV

ISIO

N

STA

RTE

R /

FEED

ER S

CO

PEPOWER SUPPLY

INTE

GR

AL

STA

RTE

R Y

/N

13 HCB10AA001 SOOT BLOWER MAIN LINE - ISOL 1 K300 1.20 6.70 4.30 415V,3PH,50HZ N V&D LTMCC R N BOP N DDCMIS EL41673 BET S3R AND S4R 02

DRG NO: 4-97-599-91191 / 02SHEET NO : 3 of 3

2091445B

4006 & 4007 VOL D1 TAB-1-68

2091445B

4006 & 4007 VOL D1 TAB-1-69

2091445B

4006 & 4007 VOL D1 TAB-1-70

2091445B

4006 & 4007 VOL D1 TAB-1-71

2091445B

4006 & 4007 VOL D1 TAB-1-72

2091445B

4006 & 4007 VOL D1 TAB-1-73

2091445B

4006 & 4007 VOL D1 TAB-1-74

2091445B

4006 & 4007 VOL D1 TAB-1-75

2091445B

4006 & 4007 VOL D1 TAB-1-76

2091445B

4006 & 4007 VOL D1 TAB-1-77

2091445B

4006 & 4007 VOL D1 TAB-1-78

2091445B

4006 & 4007 VOL D1 TAB-1-79

2091445B

4006 & 4007 VOL D1 TAB-1-80

TAB - 2

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW

BHARAT HEAVY ELECTRICALS LIMITED TIRUCHIRAPALLI-620 014

CONTROLS AND INSTRUMENTATION/FB

PUNJAB ELECTRICITY BOARD,

GURUNANAK THERMAL POWER STATION (BHATINDA - R & M),

Unit - 3 & 4, 2 x 120 MW

CUST. Nos. 4006 & 4007

WRITE-UP

ON

FURNACE SAFEGUARD SUPERVISORY SYSTEM

REVISION HISTORY

Prepared Checked Approved Rev.No.

Date Description S. Chandraleka V.M. Selvaraaj S. Ramachandran

00 27-06-2007 Initial Release -sd- -sd- -sd-

01 15-11-2007 Revised as per Customer comments -sd- -sd- -sd-

02 04-02-2008 Revised to include Reference Drawings & Note

Page 1 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-81


Reference Drawings :-

Sl.No. Description of the system Drawing No.

1 Scheme of Air and Flue gas path with Instrumentation 0-97-288-90553

2 Scheme of Pulveriser system with Instrumentation 1-97-291-90237

3 Fuel oil system LFO, HFO pumping (existing) & Heating unit 0-00-056-10672

4 Fuel oil system Boiler front arrangement 0-00-056-10673

5 FSSS Logic diagram 3-95-094-16741

to 3-95-094-16780

6 Secondary air damper control systemLogic diagram 3-95-194-16845

to 3-95-194-16852

7 Write up on Secondary air damper control system --------

Page 2 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-82


IMPORTANT NOTE

This write up is meant for general guidelines and better understanding of the system. However, it may be noted that “All the logic conditions” spelt in English Language may not be exact equivalent of pictorial representation of logics. It is mandatory that the operating personal should refer to the respective contract logics. It must be recognized that no amount of written instruction can replace intelligent thinking and reasoning on the part of boiler operators, especially when coping with unforeseen operating conditions. It is operators’ responsibility to become thoroughly familiar, not only with immediate steam generating equipment but also with all pertinent control equipment. Satisfactory performance and safety depend to a great extent on proper functioning of controls and auxiliary equipment.

Page 3 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-83

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW KEY

The logic sequences are represented in English as statements, which are to be executed in certain order of precedence as described below.

The logical gates are represented in Upper case Letters, preceeded and followed by “dots”.

eg. .AND. , .OR.

The logical function combining two statements in the same line to be executed first.

eg. xxxxxxxxxxxxxxx .AND. xxxxxxxxxxxxxxx

The logical function in the right most position is to be executed next and so on. eg. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx .AND. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx The logical function at the left most position is executed last. eg. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx .OR. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxBoth logical operators .AND.,.OR. have equal precedence between them.For better understanding the following example with mixed logical expressions is marked with the order of execution. eg. xxxxxxxxxxxxx .OR.5

xxxxxxxxxxxxx .AND.4

xxxxxxxxxxxxxxxxxxxxxxxxxx .OR.1 xxxxxxxxxxxxxxxxxxxx .AND.2

xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx .OR.3

xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx NB: xxxxxxxxxxxx represent logical statements.

Page 4 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-84

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW CONTENTS :

1. Figures (Figure-1 to 8)

2. Introduction

3. Heavy Oil Recirculation valve control

4. Furnace Purge

5. Selection of Light Oil/Heavy Oil firing

6. Oil Protection (Triple Redundant)

7. Light Oil Trip Valve Control

8. Heavy Oil Trip Valve Control

9. Light Oil Elevation start (Elevation-AB, Pair mode)

10. Heavy Oil Elevation start (Elevation-AB & CD, Pair mode)

11. Elevation Mode Operation - (Typical for LO & HO firing)

12. Pulveriser Ignition Permit

13. Pulveriser Ready

14. Pulveriser Start

15. Pulveriser in Service

16. Mill Protection (Triple Redunant)

17. Pulversier Trip

18. Pulveriser Shut-down

19. Oil Elevation Shutdown (Pair mode, Elevation-AB, LO & HO)

Page 5 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-85


20. Oil Elevation Shutdown (Elevation mode, Elevation-AB, LO & HO)

21. Unit Protection (Triple Redundant)

22. Boiler Trip conditions

23. Scanner Air Fan Control

24. Seal Air Fan Control

25. Secondary Air Damper Control

-------ooOOoo-------

Page 6 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-86


Figure-1

HFO OIL GUN

COAL + PRIMARY AIR

AIR DAMPER

BHEL SCAN

HEA IGNITOR

HFO+LFO OIL GUN

MANUAL DAMPER

AUX. AIR DAMPER

FUEL AIR DAMPER

OVER FIRE AIR DAMPER

Page 7 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-87

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 8 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-88

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 9 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-89

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 10 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-90

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 11 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-91

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 12 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-92

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 13 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-93

FSSS W

RITE

-UP, B

HA

TIND

A R

& M

, 2 x120 MW

Page 14 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-94

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW 2.0 INTRODUCTION :The Furnace Safeguard Supervisory System (FSSS) is designed to ensure the execution of a safe, orderly operating sequence in the start up and shutdown of fuel firing equipment and to prevent errors of omission and commission in following such a safe operating procedure. The system provides protection, should there be a malfunction of fuel firing equipment and associated air systems. The safety features of the system are designed for protection in most common emergency situations. However the system cannot supplement the intelligence and the reasonable judgement of the operator in all the situations. In some phases of operation, the Furnace Safeguard Supervisory System provides permissive interlocks only to ensure safe start up sequence of equipment. Once the equipment is in service, the operator must use normally acceptable safe operating practices. It is important that the operator is familiar with the overall operation of the unit and the operation of individual equipments as outlined in the various equipment sections in this manual. It is essential that all parts of the Furnace Safeguard Supervisory System are in service at all times if the system is to provide protection for which it is designed. Propermaintenance and periodic inspection of the system and associated hardware is essential for continued reliable operation. This instruction section of the system gives a complete description of the Furnace Safeguard supervisory System furnished for this unit as it is related to the various operating phases and operation of the fuel firing equipment and associated air systems. Basically the system is designed to perform the following functions : • Prevent any fuel firing unless a satisfactory furnace purge sequence has first been

completed. • Prevent start-up of individual fuel firing equipment unless certain permissive interlocks

have first been satisfied. • Monitor and control the proper component sequence (Manual or Automatic) during

start-up and shut-down of fuel firing equipment. • Make continued operation of fuel firing equipment subject to certain safety

interlocks remaining satisfied.

Page 15 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-95

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW • Provide component status feedback to the operator and in some cases, to the unit

control system. • Provide flame supervision when fuel firing equipment is in service and effect a fuel

trip upon certain adverse operating conditions. • Initiate a fuel trip when certain abnormal operating conditions exist. Furnace safeguard supervisory system (FSSS) provided for this project is designed for a natural circulation, Heavy Oil (HO) fired boiler with coal as the primary fuel and Light Oil (LO) as the start-up fuel and Heavy Oil as the fuel for warm up and stabilisation. This system provides for the remote/manual operation of two elevations of high energy arc (HEA) ignitors, two elevations of oil guns with provision for firing Light oil in elevation AB only, Heavy oil in elevation AB & CD and four pulverizers, serving four elevations of 16 coal nozzles from a remote console insert and through operator work stations (OWS) (Refer Figure-1). From the console insert Heavy oil trip valve, Light oil trip valve & HO Recirculation Valve can be opened/closed, Purge cycle can be started, Scanner Fans & Seal Air Fans can be started/stopped & Hot Air Gate can be opened/closed, Pulveriser & Feeder can be started/stopped. Indicating lights on the console insert shows the operating status of various field equipments connected to FSSS. The following operational functions are included in FSSS. • Furnace purge supervision.

• Secondary air damper modulation, on/off control and supervision.

• Light oil on-off control and supervision.

• Heavy oil on-off control and supervision.

• Pulveriser and feeder on-off control and supervision.

• Flame scanner intelligence and checking.

• Overall boiler flame failure protection.

• Boiler trip protection. `

The Furnace Safeguard Supervisory System has been designed for Energise to Open & Energise to Close philosophy. This means any on/off device or equipment has to get an impulse/command to change its present state and has to get again another impulse/command to regain to the original state.

Page 16 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-96

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW Note :-All startup and shutdown operations etc. will be possible from the Hardwired console insert and Operator work station (OWS). 3.0 HEAVY OIL RECIRCULATION VALVE CONTROL (HORV) (Refer Figure- 3)Before any main fuel can be fired the heavy oil must be brought to proper temperature. This is accomplished by recirculating HO through the oil recirculation system by means of the HOTV and HO Recirculation valve (HO Return Trip Valve). FSSS permits the opening of HOTV for oil recirculation purpose following a boiler trip and prior to starting a furnace purge cycle as follows : Depressing the "HO Recirculation valve (HORV) open Push Button" will open the Recirculation valve (long), provided all the HO nozzle valves are fully closed. When the HORV is fully open as indicated by the "HORV open" light (red) being on, depress the "HOTV open Push Button". This will start the HO recirculation. Depressing the “HO Recirculation valve CLOSE Push Button” will close the HO Recirculation valve. The HO Recirculation valve will close automatically after any corner heavy oil nozzle valve leaves the closed position. 4.0 FURNACE PURGE Before any fuel firing can take place, (initially or after a boiler trip) a successful furnace purge cycle must be completed. To start a furnace purge cycle proceed as follows:

Establish AC & DC power to FSSS and the related equipment. •

•

•

•

Place atleast one ID and one FD fan in service.

Establish airflow between 30% and 40% MCR through the furnace.

Establish a proper water level in the drum.

After the “PURGE READY” and the “PUSH TO PURGE” lights come on, a furnace purge cycle can be started. When both these lights come on it indicates that all the purge requirements are satisfied (see Note-1 below ). NOTE-1 :-

Page 17 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-97

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW If both the “ PURGE READY” and the “PUSH TO PURGE” lights do not come on after conditions 1 through 5 above are satisfied, check to see that : • The light oil trip valve is proven closed.

• All the light oil nozzle valves are proven closed.

• The heavy oil trip valve is proven closed.

• All the heavy oil nozzle valves are fully closed.

• All PA Fans are off.

• All feeders are off.

• All hot air gates are fully closed.

• All the flame scanners show No Flame (Both fire ball and discriminating scanners).

• No boiler trip command is present (See boiler trip section for specifics).

• Air flow > 30% and < 40 %

• All auxiliary dampers are modulating.

The furnace purge cycle can be started after all the purge requirements are satisfied and the “PURGE READY” light is on. The furnace purge cycle is started by depressing the START PURGE Push Button. This will start a five minutes purge timer and the “PURGING” light will come on (see Note-2 below). NOTE-2 :-Loss of the purge permissive at any time during the five minutes purging period will reset the purge timer. When this happens, the purge requirements must be re-established (“PURGE READY”) and another furnace purge cycle shall be started by depressing the “PUSH TO PURGE Push Button”. At the end of the five minutes furnace purge cycle, provided the purge permissive remain satisfied, the boiler trip is reset. This is indicated by the “MFT” light going off, the “PURGING” and “PUSH TO PURGE” lights going off. A “NO MFT” condition is now established and the “CAUSE OF TRIP” memories are reset. The operator may open the various trip valves as described in the following sections. 5.0 SELECTION OF LIGHT OIL/HEAVY OIL FIRING :-Either Light Oil or Heavy Oil can be fired at elevation AB, when selected by the operator.

Page 18 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-98

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW Depressing the “LIGHT OIL SELECT Push Button” will select light oil, provided all the HO nozzle valves and LO nozzle valves are fully closed .AND. both pairs have been stopped. When the above conditions are satisfied, the “LO SELECTED” light comes on. Depressing the “HO SELECT Push Button” will select heavy oil, provided all the HO Nozzle valves and LO Nozzle valves are fully closed .AND. both pairs have been stopped. When the above conditions are satisfied, the “HO SELECTED” light comes on. 6.0 OIL PROTECTION (TRIPLE REDUNDANT) :For oil protection, triplicate fashion has been implemented. The following signals has been computed in 2 out of 3 Logic. For Heavy Oil : • Heavy oil header temperature very low.

• Heavy oil header pressure very low.

For light oil : • Light oil header pressure very low.

7.0 LIGHT OIL TRIP VALVE CONTROL (Refer Figure-2) :- Depressing the “Light oil trip valve OPEN Push Button” after the furnace purge cycle is completed, (boiler trip reset) will open the light oil trip valve, provided the following conditions are satisfied. • Light oil supply pressure is adequate.

• Elevation AB all the light oil nozzle valves remain closed.

When the oil trip valve open condition is indicated by a RED light coming on, the “LO elevation trip” command is removed and LO Elevation Start Permit is now established. Pressing the light oil trip valve "Close" Push Button will close the valve. The light oil trip valve also closes automatically under following conditions : Master fuel trip .OR. Any light oil nozzle valve not closed .AND. Light oil header pressure very low (From 2/3 logic). .OR. Atomising air pressure very low. .AND.

Page 19 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-99

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW No Light oil Start/Stop in El. AB. The LOTV will be commanded to close on Loss of unit +24V DC. 8.0 HEAVY OIL TRIP VALVE CONTROL (Refer Figure- 3) :-Depressing the “HO Trip valve OPEN Push Button” will open the Heavy Oil Trip Valve if either of the following conditions are present: HO recirculation valve is fully open .AND. HO Trip valve open command is present .OR. All Heavy oil nozzle valves are closed. .AND. The Heavy oil supply pressure is adequate. .AND. The Heavy oil supply temperature is adequate. .AND. No MFT condition is present. When the Heavy oil trip valve is opened the “HO Trip valve OPEN” light comes on. The “HO elevation trip command” is removed. “HO Elevation start permit” is now established. The HEAVY OIL TRIP VALVE "CLOSE" command can be given by depressing the “HO Trip valve CLOSE Push Button”. This will close the HO Trip valve. This is indicated by “HOTV CLOSED” light coming on. Also the HOTV closes automatically under any one of the following conditions. Master-fuel trip .OR. The following conditions exist for more than 5 seconds : Atomising steam pressure very low .AND. No HO start/stop in any Elevation. .OR. Heavy oil Header pressure very low .AND. Any Heavy oil nozzle valve not closed. .OR. Heavy oil header temperature very low .AND. Any Heavy oil nozzle valve not closed .

.AND. Heavy oil trip valve not closed. The HOTV is commanded to close on Loss of unit +24V DC.

Page 20 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-100

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW 9.0 LIGHT OIL ELEVATION START (Elevation AB – PAIR MODE):-Light oil can be fired at elevation AB only and in pair basis. Corners 1 and 3 make one pair, while corners 2 and 4 make the other pair. The corners making up a pair are diagonally opposite. To place the light oil guns in service proceed as follows: • Select light oil firing. • Establish light oil elevation start permit by the following conditions being satisfied.

1. No master fuel trip. 2. Light oil trip valve proven fully open. 3. Pulverizer/Feeder start permit is available.

Pulverizer/Feeder start permit is established under following conditions : Nozzle Tilt Horizontal .AND. Air flow is < 40% MCR .OR. Any Oil Elevation is in service .OR. Any feeder on .AND. No MFT Pressing the associated pair start (1-3 or 2-4) PB, provided the above conditions are satisfied, will initiate a 70 seconds start time to place the associated pair of light oil guns in service. Refer to Heavy oil elevation start for the sequence of introduction of oil gun in service, which is similar. Light oil elevation trip occurs under any of the following conditions : • Master fuel trip. • Light oil trip valve not open.

10.0 HEAVY OIL ELEVATION START (Elevation-AB, PAIR MODE) (Refer Figure-4) :-(Typical for HO firing at Elevation-CD) :-Pair mode operation is selected when any one of the following conditions exists. • All coal elevations are not in service • Both coal Elevations A & B are not in service . AND. Elevation AB Back up trip exists. The warm up oil elevation can be placed in service manually, from the oil section console/operator work station (OWS), on pair basis. Either corners 1 and 3 can be placed in service or corners 2 and 4 can be placed in service. Either pair can be placed in service initially to start with.

Page 21 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-101


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The “Warm Up Elevation Start Permit” (LO elevation start permit, if LO is selected or HO elevation start permit, if HO is selected) is established if all the following conditions are satisfied. LO trip valve/HO trip valve is fully open (see “Heavy oil trip/Light oil trip valve” section for specifics). Nozzle tilts are horizontal .AND. Air flow is less than 40% MCR OR. Any Coal elevation is in service. After the HO Elevation Start Permit/LO Elevation Start Permit is satisfied, either pair can be placed in service in the following manner. Initially, let us assume that pair 1 and 3 is to be placed in service. Pressing “PAIR 1-3 START Push Button” for the elevation being started, will cause the following events :

The “PAIR 1-3 START” light is illuminated and the associated “PAIR 1-3 STOP” light goes off.

The seventy second elevation start (for corner No.1 and 3) counting period is reset.

The “Elevation Back Up Trip” signal is removed, positioning the associated elevation dampers for “warm up oil firing”. When the Push Button is released, the seventy second counting period is started and corner-1 receives a “start” command instantaneously and corner-3 receives a “start” command after 15 seconds. After the “start” command is established for corner-1, the corner oil gun will be placed in service if all the following conditions at corner-1 are satisfied.

The associated corner scavenge nozzle valve is closed.

The associated corner manual atomising (air/steam) isolation valve is open.

The local maintenance switch at the associated corner is placed in the “REMOTE”

position.

When “start” command is established at corner-1, the HEA ignitor gets advance command provided all the following conditions are satisfied.

LO Nozzle valves and HO Nozzle valves are closed.

Page 22 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-102

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW •

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Discriminating flame scanner shows no flame.

When the spark rod of HEA ignitor is fully advanced, the HEA Rod “ADVANCED” light comes on. Atomising valve gets open command if oil gun is engaged. Once the atomising valve is fully opened, oil nozzle valve gets open command and the exciter of HEA ignitor is energised. The corner oil nozzle valve (LO/HO) receives an “open” command provided if all of the following conditions are satisfied.

The corner is not in scavenge.

Atomising nozzle valve (Air/Steam) is proven open.

None of the corner trip condition is present .AND. HEA Ignitor spark rod is in

“advanced” position.

Corner warm-up nozzle valve is not closed .AND. Discriminating scanner shows flame.

When the corner oil nozzle valve (LO/HO) is in “open” condition, then a 15 seconds trial time for the HEA ignitor is initiated. When the corner oil nozzle valve (LO/HO) is proven open, the oil nozzle valve “OPEN” light comes on. At the end of the 15 seconds ignitor trial time, HEA exciter is de-energised and HEA ignitor is retracted. If the associated corner discriminating scanner indicates flame the “DISCRIMINATING SCANNER FLAME” light comes on. Corner-1 oil gun (LO/HO) is now in service. When the 15 seconds counting period expires, corner-3 oil gun start command is established and will be placed in service in the same manner as previously described for corner-1. When the seventy second counting period expires (for corner 1 & 3), the fifteen second timer for corner 3 is reset and oil gun in Corner-1 & 3 will be shut down if the associated oil nozzle valve is not fully open. Corner No. 2 and No. 4 are placed in service by the associated “PAIR 2-4 START Push Button”. The following events will occur :

The “PAIR 2-4 START” light is illuminated and the associated “PAIR 2-4 STOP” light

goes off.

The seventy second elevation pair( for corners 2 and 4 ) counting period is reset.

Page 23 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-103

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW When the Push Button is released, the 70 second counting period is started. The “Start” command for corner 2 is established and a fifteen second counting period, to establish a “Start” command for corner 4 is started.

After the “Start” command is established, the associated corner oil guns (LO/HO) are placed in service in the same manner as previously described for corner 1. When atleast three of the four warm-up oil (LO/HO) Nozzle valves are fully open, the warm-up oil elevation (LO/HO) is in service. This is indicated by the “IGNITION PERMIT” light coming on the Coal Elevation console/operator work station (OWS) for the mill associated with the warm-up oil elevation. The “Ignition permit” is now satisfied and the associated mill can be placed in service after other permissives are satisfied. When the seventy second counting period (for corners 2 & 4) expires, the fifteen seconds timer for corner 4 is reset and the oil gun in Corner-2 & 4 will be shut down if the associated oil nozzle valve is not fully open. 11.0 ELEVATION MODE OPERATION (TYPICAL FOR LO & HO FIRING) (Refer Figure-4) :-Elevation mode operation is automatically selected when either of the adjacent coal elevations associated with warm-up (LO/HO) oil elevation is in service. When the above condition exists, the “Elevation Mode Operation” is automatically selected and the associated warm-up (LO/HO) oil elevation is placed in service in the following manner (provided the “warm-up elevation start permit” remains satisfied). When pair 1-3 start or pair 2-4 start PUSH BUTTON is pressed, an “Elevation Start” command is established for corner 1 & 3. After the “Elevation Start” command is established, a forty second counting period is started to establish an “Elevation Start” command for corners 2 & 4. Corners 1 & 3 are now placed in service as previously described in the “Pair Mode Operation” section. When the forty second counting period expires, corners 2 & 4 are placed in service as previously described in “Pair Mode Operation” section. When atleast three of the four warm-up (LO/HO) nozzle valves are fully open , the warm-up (LO/HO) elevation is “proven in service”. An “Elevation Unsuccessful Start” condition is established when both seventy second counting period expires and if less than three warm-up (LO/HO) nozzle valves are in service.

Page 24 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-104

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW When an “Elevation Unsuccessful Start” signal is established, two seconds later, corner 1 and 3 receive “Stop” command and a forty second counting period is started. Forty seconds later corners 2 and 4 receive “Stop” commands. An “Elevation Unsuccessful Start” condition initiates an alarm. All four corners are shut down (see “warm-up oil elevation shutdown” section for specifics). 12.0 PULVERIZER IGNITION PERMIT:-Prior to start any feeder, the pulveriser ignition energy must be adequate to support coal firing. This is accomplished as follows: PULVERIZER-AA minimum of 3 of the 4 Elevation-AB oil nozzle valves proven open. . OR. Boiler loading is greater than 30% .AND. Feeder-B is in service at greater than 50% loading

PULVERIZER-BA minimum of 3 of the 4 Elevation-AB oil nozzle valves proven open. .OR. Boiler loading is greater than 30% .AND. Feeder-A .OR. C is in service at greater than 50% loading. PULVERIZER-CA minimum of 3 of the 4 Elevation-CD heavy oil nozzle valves proven open. .OR. Boiler loading is greater than 30% .AND. Feeder-B .OR. D is in service at greater than 50% loading. .OR. A minimum of 3 of the 4 Elevation-AB heavy oil nozzle valves proven open .AND. Feeder-B is in service at greater than 50% loading. PULVERIZER-DA minimum of 3 of the 4 Elevation-CD heavy oil nozzle valves proven open. .OR. Boiler loading is >30% .AND. Feeder-C is in service at greater than 50% loading. 13.0 PULVERIZER READY (Refer Figure-8):-Prior to starting a pulverizer, a pulverizer start permit condition for the respective pulverizer must be established by confirming the following conditions being satisfied :

Page 25 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-105


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Each condition is indicated by a yellow light on console/operator work station (OWS).

Pulverizer/Feeder start permit.

Pulverizer discharge valve open.

Pulverizer outlet temperature not high.

Cold air gate open.

Tramp iron hopper valve open.

Primary air permit .OR. pulverizer on.

Auto pulverizer No unsuccessful start.

All Burner isolation gate open.

Pulveriser no trip.

Lube oil system healthy. When all the above conditions are satisfied for the respective pulverizer, its associated pulverizer ready condition is satisfied. 14.0 PULVERIZER START:-Pulverizer and the associated equipments can be started either automatically or manually. Auto/Manual mode of pulverizer start can be selected by means of selector pushbuttons provided on coal Elevation console/operator work station (OWS). 14.1 PULVERIZER START (MANUAL MODE):- By establishing Ignition energy available and pulverizer ready conditions for the respective pulverizer, it may be placed in service as follows: • Ensure pulverizer ready condition and ignition energy available condition are present.

Start pulverizer by pressing its associated "START” Push Button. First, seal air valve opens, after seal air to bowl DP adequate is established, pulverizer will start.

• When the pulverizer is proven on as indicated by the (Red) pulverizer "ON" light, open

the hot air gate by pressing its "OPEN" button and allow the pulverizer to come up to the temperature.

Page 26 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-106

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW • When the pulverizer comes up to temperature, (approximately more than 49 deg. C-

say around 70 deg. C) start the feeder by pressing its associated "START” Push Button. Coal flow must be proven either by the coal flow detector or satisfactory pulverizer current within 5 seconds, after the feeder is started.

• Fifteen seconds after the feeder is started, the feeder output is released to the

include feeder in the totalising circuit. • When the feeder is ON for 50 secs. the feeder speed is released to auto control

and the fuel air dampers are opened to modulate as a function of feeder speed. • When a minimum of two feeders are established at greater than 50% loading, the

associated oil elevations may be shut down provided the feeder has been ON for a minimum of 3 minutes.

OPERATOR’S NOTE :-A single feeder in service for fifty seconds at its minimum speed setting will establish a fireball in the furnace (a single fireball is established when a coal elevation is placed in service. When additional coal elevations are placed in service, this single fireball is merely enlarged). If the support ignition energy is removed, the fireball will be monitored by the associated elevation flame scanners. However, good operator procedure dictates that an adjacent feeder must be placed in service and both feeder speeds be increased to 50% before removing the support of the fireball. When removing feeders from service, the inverse procedure should be followed and support ignition energy should be reinstated when only two feeders remain in service at 50% feeder speed. 14.2 PULVERIZER START (AUTO MODE) :-The selected pulverizer can be placed in operation automatically if all the following conditions are satisfied: • The associated " Pulverizer Ready “ condition remains satisfied. • The " AUTO " mode is selected for the associated pulverizer. The pulverizer is started by momentarily pressing the pulverizer "start" Push Button. The following events will occur : a) A 180 second counting period is started to prove the associated pulverizer / feeder in service. b) If the pulverizer ignition energy permissive is not satisfied an "Start Oil Elevation Auto” command is established and the associated HFO elevation is automatically placed in operation. (Refer to " Elevation Mode of Operation" section for details).

Page 27 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-107


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c) When the associated support ignition elevation start time has expired (both seventy second "Pair start" counting periods have expired) and the pulverizer ignition permissive is satisfied, the "Auto start pulverizer" and "Open hot air gate" commands are established simultaneously. d) A pulverizer "Start" command is established and the pulverizer is started in the same manner as previously described in pulverizer manual mode. e) When the pulverizer is proven ON the following events occur:

The hot air gate is opened, provided the pulverizer outlet temperature is less than High Value (94 Degree C).

A sixty second counting period is started to establish an "Auto start feeder" Command.

f) When the sixty second counting period expires, an "auto start feeder" command is established for five seconds. A "start feeder " command is now established, provided the hot air gate is open. The feeder is put into service in the same manner as previously described. After the 180 second "elevation start" counting period expires and the pulverizer is on and the feeder is off, the unsuccessful elevation start is established. When the feeder is off for more than three minutes, the pulverizer receives an "auto stop pulverizer" command and is shutdown. 15.0 PULVERIZER IN SERVICE (Refer Figure-8 ):-With the pulverizer/feeder in service, several operational parameters are continuously monitored. However, it is left to the operator’s discretion to investigate and take further corrective action. An operating pulverizer and feeder are subject to the following operational checks : • The feeder speed will be run back to minimum if the pulverizer bowl differential

pressure is high .OR. if the respective Pulveriser Motor current is High. • If the pulverizer outlet temperature is high (greater than 94 Degree C), then the

following events occur:

i) Pulverizer air and temperature control is released from auto mode. The hot air dampers close and the cold air dampers open to 100% pulverizer air flow position.

ii) The hot air gate is closed after a thirty second time delay to allow the

associated dampers to react.

Page 28 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-108


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Any of the following conditions will give signal to run the feeder speed to minimum until the initiating condition is corrected.

Pulverizer bowl differential pressure high. Feeder is off.

Loss of coal flow and low pulverizer current will trip the feeder and close hot air damper. The operator should take appropriate corrective action, then reopen the hot air damper and restart the feeder. High pulverizer outlet temperature (above 94 deg. C) will open cold air damper and close the hot air damper. It will close Hot Air Gate after 30 sec delay. 16.0 MILL PROTECTION (TRIPLE REDUNDANT) :Mill protection system is governed by the mill trip logic. Triplicate fashion has been implemented for the following signal for all mill elevations as a part of unit protection logic. • PA pressure very low.

17.0 PULVERIZER TRIP (Refer Figure-5, 7 & 8) :- The following conditions will initiate a pulverizer trip command.

Pulverizer discharge valve not open. •

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Loss of unit +24V DC power.

Pulverizer ignition permit is not available .AND. support ignition required.

MFT (See boiler trip section for details).

Loss of primary air

Seal air header to Pulverizer differential pressure low .AND. Pulvurizer on for more than 60 seconds.

Lube oil system failed.

Any burner isolation gate not open.

Pulveriser failed to start for more than 10 seconds.

Page 29 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-109


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Hot Air Gate Closed & Cold Air Gate Not Open When the primary air duct pressure falls below the low set point (for more than 5 secs.) all pulverizers in service a receive stop command. When both PA fans stop or the primary air duct pressure goes very low, all the pulverizers are tripped instantaneously. When one PA fan or one FD fan trips and three or more pulverizers are in service, each pulverizer with a 2 sec time delay a trip command will be given starting from the pulverizer serving top most coal elevation, until the number of pulverizers remaining in service is reduced to two. 18.0 PULVERIZER SHUT DOWN :- 18.1 PULVERIZER SHUT DOWN (MANUAL MODE) :-When manual pulverizer control mode is selected, manual shut down of a pulverizer is accomplished as follows: • Start the associated oil elevation, if it is not in service. • Reduce the feeder speed to minimum. • Close the hot air gate by pressing its "CLOSE" Push Button. • When the pulverizer outlet temperature is reduced to (below 49 deg C or 120 deg F),

then shut down the feeder by pressing its "OFF" Push Button. • Allow the pulverizer to run for about 2 minutes to ensure that it is completely empty

of coal, then shut down the pulverizer by pressing its "OFF" Push Button. 18.2 PULVERIZER SHUTDOWN (AUTO MODE) :-When the Pulverizer is in the auto mode of operation, the pulverizer is shutdown as described below.

a) The operator initiates a pulverizer auto shutdown sequence by momentarily depressing the associated "Stop” pushbutton. The following events will occur.

i) The "auto stop memory" signal is established and the "Auto start memory" is reset. ii) If the associated pulverizer ignition permissive is not satisfied, an "Auto start support ignition energy" command is established.

Page 30 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-110


iii) A ten minutes "Elevation stop" counting period is started.

b) When the support ignition time has expired (both seventy second HO pair starting Periods have expired) and the pulverizer ignition permissive is satisfied, then the following commands are established simultaneously.

i) Run the feeder speed to minimum. The feeder speed will be reduced through auto control. ii) Close hot air gate in auto mode. The associated hot air gate is closed in the manner previously described (see Pulverizer Manual Shut down section).

c) When the hot air gate is closed and the pulverizer outlet temperature has been

reduced below 49 degree C (120 degree F), the associated feeder will receive an "Auto stop" Pulverizer command. The feeder will now be shut down.

d) When the feeder is off for three minutes, the associated pulveriser will

receive an "Auto stop" pulveriser command. The pulveriser will now be shut down.

The associated H.O elevation can be shut down when the furnace and boiler conditions have stabilised. When the ten 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 at the associated coal elevation:

i) The Pulveriser is on. ii) The Feeder is on. iii)The Hot air gate is not closed.

HOT AIR GATE CONTROL :-Pressing Hot Air Gate “OPEN” Push Button on, will open the gate if following conditions are present. Pulveriser on .AND. Pulveriser auto start .OR. Pulveriser manual mode .AND. Close Hot air gate command is not available. “Red” lamp will indicate open state of the gate. Hot Air Gate will close automatically if following conditions are present.

Page 31 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-111

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW Close Hot Air Gate command present for more than 30 seconds. .OR. MFT .OR. pulveriser off Loss of unit +24V DC will also close the Hot Air Gate. This is indicated by “Green” lamp. 19.0 OIL ELEVATION SHUTDOWN (Pair mode Elevation-AB, LO & HO) :-(Typical for HO firing at Elevation-CD) When adjacent coal elevations are not in service and elevation back up trip exists or when all coal elevations are off, the associated warm-up (LO/HO) elevations are automatically selected to the “Pair operation Mode” and the warm-up (LO/HO) elevation can be shut down, pair-wise. Under “pair operation mode” the oil elevation is removed from service in the following manner. Either pair (1-3) or (2-4) can be initially shutdown. Each pair of oil guns are shutdown in the following manners. Pressing “PAIR (1-3 or 2-4) STOP” Push Button momentarily will establish a stop signal for that pair. This will cause the following events to occur : A 375 second elevation “Pair Stop” counting period is started. The associated Elevation “PAIR (1-3 or 2-4) STOP” light comes on. A “Stop” command for corner 1 (or corner 2) is established, and a fifteen seconds counting period is started to establish a “Stop” command for corner 3 (or corner 4). The corner oil (LO/HO) nozzle valve will receive a “CLOSE” command. (When the corner oil nozzle valve is moved to the fully closed position, the oil valve “CLOSED” light comes ON and the associated “DISCRIMINATING SCANNERS NO FLAME” light comes on.) After the warm-up (LO/HO) nozzle valve is closed, the scavenge nozzle valve receives “Open” command. Also the spark rod of HEA is advanced and gives spark for a period of 15 seconds. After the scavenge valve is fully open, a five minute counting period is started.

Page 32 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-112

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW After the five minutes scavenge trial time expires, the Scavenge valve receives “Close” command. When the Scavenge valve is moved from the fully open position, the five minute counting period is reset. When the Scavenge valve is closed, the associated atomising (Air/Steam) nozzle valve receives a “Close” command. When the fifteen second counting period expires, a “Stop” command is established for corner 3 (or corner 4) which is removed from service in the same manner as previously described for corner 1 (or corner 2). After the pair stop time expires, the scavenge valve memory is reset. The other pair (1-3 or 2-4) is stopped similarly by depressing the “PAIR STOP” Push Button. (see Note-4 below). NOTE -4 :-Simultaneously, a 360 second counting period is started to establish a “warm-up” elevation back up trip after the first pair (1-3 or 2-4) of oil guns have been shut down and the “Stop” command for the first oil gun of the second pair (1-3 or 2-4) is established. The associated pair of oil guns are shut down in the same manner as previously described for the other pair of oil guns (1-3 or 2-4). When the 360 second counting period expires, a warm-up “Elevation Back up trip” condition is established. This pair “Back up trip” establishes a redundant “Stop” command to ensure that the oil guns are shut down. The signal to “Position the warm-up oil elevation dampers for warm-up fuel firing” is removed. After the “warm-up oil elevation back up trip” is established, an “Unsuccessful warm-up oil elevation shut down” condition is established when both 375 second counting period expire and any warm-up (LO/HO) nozzle valve is not closed or any HEA Ignitor is not retracted in the associated elevation. This initiates “Oil Elevation Unsuccessful Shut down” alarm. A warm-up oil (LO/HO) gun may also be shut down and scavenged individually by placing its local gun maintenance switch in the “SCAVENGE” position. The warm-up oil gun will be shut down and scavenged as described above. To return the warm-up oil gun to service, return the local gun maintenance switch to “REMOTE” position and depress the associated warm-up oil elevation “PAIR START” Push Button.

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2091445B

4006 & 4007 VOL D1 TAB-2-113


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Any one of the conditions listed below will trip an individual warm-up oil corner by issuing a corner trip signal.

Associated local maintenance control switch turned to “OFF” position.

Warm-up oil gun not engaged.

Atomising (Air/Steam) Manual isolating valve not open.

Corner not in scavenge .AND. Corner start time expired .AND. Warm-up oil nozzle valve not open .OR. Atomising steam nozzle valve not open .OR. Discriminating scanner no flame Elevation back up trip. LO (HO) selected when HO ( LO) is fired.

20.0 OIL ELEVATION SHUTDOWN (Elevation mode, Elevation-AB, LO & HO):(Typical for HO firing at Elevation CD)When either of the coal elevation associated with the warm-up oil elevation, is in service, the warm up oil elevation can be shut down under this elevation mode. The subject elevation can be shut down as described in the following section. Under Elevation mode, the oil elevation is removed from service in the following manner. Pressing the “PAIR STOP” Push Button. (1-3 or 2-4) will establish a corner “STOP” command. The “PAIR STOP” command will establish a corner “STOP” command provided both coal elevations associated with the warm-up elevation have been ON for at least three minutes or both associated coal elevations are not in service. The corner “STOP” command will cause the following events to occur :

A 375 second elevation pair counting period is started for corner 1 and 3. •

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A forty second counting period is started to establish a “STOP” command for corner 2 and 4.

Page 34 of 42

2091445B

4006 & 4007 VOL D1 TAB-2-114

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW The Elevation “PAIR 1-3 STOP” light comes on. A “STOP” command for corner 1 is established and a fifteen second counting period is started to establish a “STOP” command for corner 3. After the “STOP” command is established, the oil gun at corner 1 is removed from service in the same manner as previously described. When the fifteen second counting period expires, the “STOP” command for corner 3 is established and is removed from service in the same manner as corner 1. When the forty second counting period expires, the “STOP” command is established causing the following events to occur. A 375 second elevation pair counting period is started for corners 2 and 4. The Elevation “PAIR 2-4 STOP” light comes on. Corner 2 stop command is established and a fifteen second counting period is started to establish a stop command for corner 4. The oil gun at corner 2 is removed from service in the same manner as previously described. When fifteen second counting period expires the “STOP” command for corner 4 is established and is removed from service in the same manner as corner 2. All other interlocks i.e., Backup trip, elevation unsuccessful shutdown etc. are same as described earlier.

21.0 UNIT PROTECTION :-For unit protection, triple redundant fashion has been implemented for the following contact signals (three contacts each ). All the three contacts are distributed to the redundant protection system. • Furnace pressure very high.

• Furnace pressure very low.

• Drum level very high.

• Drum level very low.

• Air Flow < 30 %.

• Loss of Reheater Protection.

• Spare trip.

All the above conditions are processed in 2 independent sub systems and 2 out of 3 voting are done in individual processor.

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2091445B

4006 & 4007 VOL D1 TAB-2-115

FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW In addition to the above , the internally generated trip signals like • Loss of all fuel trip.

• Flame failure trip.

• Less than Fire ball and loss of AC.

are processed in the above two processors for 1 out of 2 voting for formalising the MFT condition. 22.0 BOILER TRIP CONDITIONS :- 22.1 MASTER FUEL TRIP (MFT)Master Fuel Trip is initiated by any one of the following conditions :

Less than fire ball and loss of AC at any elevation in service (See the NOTE-5). ••••••••••••••

Drum water level very low for more than 5 seconds. Drum water level very high for more than 10 seconds. Both FD Fans off. Both ID Fans off. Air flow is less than 30% Furnace pressure very low. Furnace pressure very high. Loss of all fuel trip (See the NOTE-6) Unit flame failure trip (See the NOTE-7) Both emergency trip Push Buttons pressed (Operator initiated boiler trip) Spare trip. Loss of Reheater protection. Loss of 220V DC for more than 2 second.

NOTE-5 :-“Less than fire ball and loss of AC in any elevation in service” condition occurs, when all the mills are not in service and there is a loss of power supply (24 V DC-for Solenoids) at any of the elevation in service. Under this condition as ignition energy will not be proper (no fire ball), the HO elevation (Oil) cannot be allowed to run without control (as there is no power supply). Hence the boiler has to be tripped to shut down the elevation. NOTE–6 :-“Loss of All Fuel Trip” circuit is armed as soon as oil firing is introduced into the furnace, through any one of the following conditions. i.e. if any oil burner comes into service. This condition also indicates that the “Boiler is on”.

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FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW This condition is generated when any one of the following condition occurs : Elevation AB any LO nozzle valves not closed Elevation AB any HO nozzle valves not closed Elevation CD any HO nozzle valves not closed 22.2 LOSS OF ALL FUEL TRIP :“Loss of All Fuel Trip” condition is generated if all the following conditions exist along with “Loss of all fuel trip arming” condition. All feeders are off .AND. Elevation AB Backup trip .OR. All LO valves are closed .OR. LO trip valve is not open .AND. Elevation AB back up trip .OR. All HO valves are closed .AND. Elevation CD back up trip .OR. All HO valves are closed .OR. HO Trip Valve not open. Loss of all fuel trip arming memory is reset 5 seconds after MFR trip occurs. 22.3 UNIT FLAME FAILURE :- “Unit Flame Failure Trip” occurs if all the six elevations vote for No flame along with the arming signal. Conditions for the generation of No Flame voting Elevation wise is given below : ELEVATION-AFeeder-A is not proven. .OR. Elevation-AB 3 out of 4 Fireball scanners show no flame .AND. HO/LO 2 out of 4 nozzle valves not open . .OR. Elevation-AB started and loss of power. ELEVATION-BFeeder-B is not proven .OR. Elevation-AB 3 out of 4 Fireball scanners show no flame .AND. HO/LO 2 out of 4 nozzle valves not open . .OR.

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FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW Elevation-AB started and loss of power. .AND. Elevation-BC 3 out of 4 fire ball scanners show no Flame ELEVATION-CFeeder-C not proven . .OR. Elevation-CD 3 out of 4 Fireball scanners show no flame .AND. HO 2 out of 4 nozzle valves not open . .OR. Elevation-CD started and loss of power. .AND. Elevation-BC 3 out of 4 fire ball scanners show no flame ELEVATION-DFeeder-D not proven. .OR. Elevation-CD 3 out of 4 Fireball scanners show no flame .AND. HO 2 out of 4 nozzle valves not open . .OR. Elevation-CD started and loss of power.

.AND. Elevation-DD 3 out of 4 fire ball scanners show no flame NOTE-7 :-“Unit Flame failure Trip” circuit is armed 2 seconds after any coal elevation is put into service. 22.4 FIRST OUT TRIP SYSTEM :- A First Out Trip System provided allows the operator to determine the cause of a boiler trip by observing the indication lamps located on the Unit console/operator work station (OWS) under First Cause of Trip. When an event that causes occurrence of boiler trip, the associated “Cause Of Trip” memory is set, and the indicating lamp for trip command, responsible for the boiler trip is illuminated and the successive trip commands to the other indications are blocked. When the event that caused the boiler trip is corrected & boiler purging is completed the “Cause Of Trip” memory is reset. This indicates that a “No Boiler Trip Command” is established. The memories are reset automatically after a successful 5 minute furnace purge cycle has been completed. The FIRST CAUSE OF TRIP light that caused the boiler trip will go off.

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22.5 POST PURGE EXCURSION PROTECTION :- Post purge excursion protection circuit has been designed in the Furnace Safeguard Supervisory System. It operates as described below: When all the following conditions are satisfied, a 5-minute counting period is started.

Light oil trip valve closed. ••••••••••

Elevation AB all LO nozzle valves closed. Heavy oil trip valve closed. All elevation all HO nozzle valves closed. All Feeders off. Air flow > 30 % MCR and <40 % MCR. All scanners show “no flame”. All Hot air gates closed. All aux. air dampers modulating All PA fans off.

After 5 minute counting period expires, the “Post Purge Fan Trip” memory is set, if very high or very low furnace pressure exists, the post purge fan trip command is issued (for tripping FD&ID fans). When any HO / LO valve is open, this is reset. 22.6 FEED FORWARD COMMAND TO FURNACE DRAFT CONTROL :- A 30 seconds Feed Forward command to Furnace draft control is given if either of the conditions listed below exists.

Loss of unit +24V DC power •• Occurrence of Master Fuel Trip, when the boiler is on (i.e., Loss of all fuel trip

arming is present). 22.7 FURNACE PRESSURE RECORDER SPEED CHANGE :- This contact has been provided to switch the Furnace Pressure Recorder to the alternate speed (if Dual speed recorder is provided) under the conditions mentioned below, to observe Furnace Draft fluctuations.

MFT •••

Loss of unit +24V DC power Furnace Pressure High or Low

For condition 1 & 2 mentioned above, the Recorder speed is reverted back to original value after 30 seconds. For condition 3, the Recorder is set to original value 30 seconds after condition 3 is removed.

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FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW 23.0 SCANNER AIR FAN CONTROL (Refer Figure 6):- Scanner fan “A” or “B” can be started manually by depressing the respective “START PB”. Scanner fan “A” or “B” will start automatically whenever the scanner duct to furnace differential pressure goes below 150 mm W.C. .AND. No MFT .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, the other scanner fan will start automatically. Scanner fans A or B can be stopped by depressing the respective “STOP PB” provided there is No start command .AND. Scanner duct to furnace differential pressure is more than 150mm W.C. When both the FD fans are off .OR. Loss of unit +24 V DC, scanner emergency damper will open automatically. Damper closes automatically when any FD fan is ON. 24.0 SEAL AIR FAN CONTROL (Refer Figure-7):-There are two seal air fans that serve this unit, one working and one standby. Any seal air fan can be started manually by depressing its “START PB”. This action gives start command to the motor. The seal air fan which is not in service, is started on Auto command if, Any PA fan is on .AND. Seal air header to cold PA header DP is low for > 10 secs. The seal air fan “A” will start automatically 5 second after the seal air fan “B” trips or fails to start on receiving start command (SA fan “B” starts automatically if SA fan “A” fails to start). Any seal air fan can be stopped by depressing its “STOP PB”, provided the following conditions are satisfied. Seal Air Header / Cold Air duct DP not low .AND. Both Seal Air fans on Both Seal Air Fans are tripped once Both PA Fans are off > 15 Secs.

25.0 SECONDARY AIR DAMPER CONTROL:-For a complete description of the Secondary Air Damper Control, refer the write up on SADC system. Operation of the secondary air damper control as effected by the FSSS is described here.

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FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW 25.1 AUXILIARY AIR DAMPER CONTROL All elevations of the aux. air dampers will be automatically switched to “Manual” control and then commanded to open 100%, if any one of the following conditions exist.

All FD fans are off ••••

•

•

All ID fans are off Master fuel trip exists (for more than 2 seconds PULSE) Loss of Unit +24 V DC power

When the auxiliary air control is placed in the “Auto” mode of operation, the auxiliary air dampers modulate to control wind box to furnace differential pressure at a predetermined set point. During the furnace purge cycle, all auxiliary air dampers modulate to maintain wind box to furnace differential pressure at a predetermined set point. When the unit load exceeds 30% of MCR, the following events occurs : The wind box to furnace differential set point is gradually increased as the unit load is increased. Conversely, the differential pressure set point is gradually decreased as unit load is decreased. The rate of increase (or decrease) is controlled by the auxiliary damper controller. When the Unit Load is increased above 30% MCR, the Auxiliary air dampers on elevation AB, BC, CD & DD are closed in a timed sequence (10 seconds interval) provided the associated coal elevations are not in service and the associated oil elevations are not in service. The auxiliary air dampers are closed, starting from the top elevation, progressing towards the lowest elevation. When the unit load is reduced below 30% of MCR, the following events occur:

The wind-box to furnace differential pressure set point reverts to its original value.

The auxiliary air dampers associated with the coal and LO/HO elevations not in service are opened in a timed sequence (10 second interval) starting at the lowest elevation, progressing towards the top.

When a LO/HO Elevation is started (i.e. when the associated “elevation back-up” trip is removed) the associated auxiliary air dampers in that elevation are set to preset position for LO/HO firing.

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FSSS WRITE-UP, BHATINDA R & M , 2 x120 MW When the “Post Trip Purge Time Expired” command is established and all FD / ID fans are not off and a Master fuel trip” command doesn’t exist, then a 35 seconds counting period is started. After it expires, the “Open All Auxiliary Air Dampers” command is removed from memory. 25.2 FUEL (COAL) AIR DAMPERS CONTROL :-All elevations of fuel air dampers are commanded to open 100% when any one of the following conditions exist. All FD fans are off All ID fans are off Master fuel trip exists (for more than 2 seconds PULSE) Loss of Unit +24V DC power When a coal elevation is in service, the associated fuel air dampers modulate as a function of feeder speed as indicated by the associated coal elevation “MODULATING” light coming on. When the coal elevation is shut down, the associated fuel air dampers are closed, as indicated by a “CLOSED” light . When the “Post Trip Purge Time Expired” command is established and all FD and ID fans are not off and a “Master fuel trip” command does not exist, the “Open upper fuel air dampers (elevation C & D)” command is removed from memory. Thirty seconds later, the “Open lower fuel air dampers (elevation B & A )” command is removed from memory.

-------ooOOOoo-------

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SADC WRITE-UP, BHATINDA R & M , 2 x120 MW

BHARAT HEAVY ELECTRICALS LIMITED, TIRUCHIRAPALLI-620 014

CONTROLS AND INSTRUMENTATION/FB

PUNJAB ELECTRICITY BOARD,

GURUNANAK THERMAL POWER STATION (BHATINDA - R & M),

Unit - 3 & 4, 2 x 120 MW

CUST. Nos. 4006 & 4007

WRITE-UP

ON

SECONDARY AIR DAMPER CONTROL SYSTEM

REVISION HISTORY

Prepared Checked Approved Rev.No. Date Description

S. Chandraleka V.M. Selvaraaj S. Ramachandran 00 13-06-2007 Initial Release

C:\DOCUMENTS AND SETTINGS\4172485\DESKTOP\BHATINDA SADC WRITE UP.DOC

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BHATINDA – R & M – 3 & 4 SADC WRITE UP

IMPORTANT NOTE

This write up is meant for general guidelines and better understanding of the system. However, it may be noted that “All the logic conditions” spelt in English Language may not be exact equivalent of pictorial representation of logics. It is mandatory that the operating personal should refer to the respective contract logics. The various set point values, damper position values and the characteristics shown in the relevant figures and control schemes are only indicative values for start-up/initial operations. However, the same have to be adjusted for proper operations as detailed in the control philosophy (under 4.0) It must be recognized that no amount of written instruction can replace intelligent thinking and reasoning on the part of boiler operators, especially when coping with unforeseen operating conditions. It is operators’ responsibility to become thoroughly familiar, not only with immediate steam generating equipment but also with all pertinent control equipment. Satisfactory performance and safety depend to a great extent on proper functioning of controls and auxiliary equipment.

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CONTENTS

1.0 FIGURES (FIGURE-1 TO 4) 2.0 INTRODUCTION

3.0 DESCRIPTION & TERMINOLOGY

4.0 CONTROL PHILOSOPHY

5.0 OPERATION

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Figure-1

HFO OIL GUN

COAL + PRIMARY AIR

AIR DAMPER

BHEL SCAN

HEA IGNITOR

HFO+LFO OIL GUN

MANUAL DAMPER

AUX. AIR DAMPER

FUEL AIR DAMPER

OVER FIRE AIR DAMPER

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FIGURE-2

BOILER LOAD (%)

FURN

ACE

TO

WB

DP

(mm

)

0 300

40

60

60 10045

100

Note :-

1. The Arrow indicates that thevalues are adjustable at Site.

2. The DP values indicated are values during initial commissioning/operation. Final DP valuesare to be decided at Site.

be decided at Site0

5

20

25 60 100

FUEL

DA

MPE

R O

PEN

ING

(%)

FEED RATE (%)

0

FIGURE-3

Note :-

1. The Arrow indicates that thevalues are adjustable at Site.

2. The Fuel Air Damper opening (%) as indicated are to Start with duringcommissioning/operation. Final valueof Fuel Air Damper % opening are to

500

100

75 100

OFA

DA

MPE

R O

PEN

ING

(%)

BOILER LOAD (%)

FIGURE-4

OFA -

Lower

OFA -

Upp

er

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2.0. INTRODUCTIONIn tangential firing concept, the furnace itself constitutes the burner. Fuel and air are introduced into the furnace through four wind box assemblies. Fuel and air nozzles in the corners are pointed in a line, tangent to an imaginary circle, at the centre of the furnace. The result of this arrangement is a rotating swirling action that is very effective in mixing the burning fuel with secondary air. The total combustion air flow supplied in the boiler consists of two parts, one, the primary air, which is used for drying and transporting the coal from the pulveriser through the coal piping into the furnace and is supplied by the primary air fans and two, the secondary air sent through the four corners of the wind box and is supplied by the FD fans. The total secondary air flow is controlled by forced draft fan, in proportion to the fuel being fired. Total air secondary flow is measured by a flow metering device called aero-foil meter. The measured air flow is compared against the fuel flow, with the resultant signal positioning the FD fan inlet guide. This inlet guide is positioned to maintain the required air flow regardless and independent of secondary air damper position.

The secondary air dampers located in wind box apportions the total air between various elevations. How this air is proportioned depends on which fuel is being burnt, the number of elevations in service and the firing rate at each elevation.

The function of Secondary Air Damper Control (SADC) System is to proportion the total air around the firing elevation as per the criteria spelt above. In fact the SADC system is a combination of both analog and digital system, as the amount of fuel fired and the number of firing elevations decide the damper position.

Prior to stepping into control philosophy and damper operation it is essential to distinguish the different terminology associated with secondary air.

3.0. DESCRIPTION AND TERMINOLOGY (Refer Figure-1)In total, each wind box assembly is divided into 9 compartments. Each compartment is designated either by single or double alphabet constituting 9 elevations. An elevation designates all the four corner compartments.

There are 4 elevations which houses Coal nozzles for firing the main fuel. These are designated with single English letter “A” through “D”. There is one elevation (designated as AB) which houses oil burner assembly for firing start up/stabilizing fuel viz., Light Fuel Oil (LO) and Heavy Fuel Oil (HO). The elevations designated as AB & CD are housed with oil burner assembly for firing Heavy Fuel Oil (HO). Each oil compartment is interposed between two Coal nozzle assemblies. There are two numbers of over fire air compartment at the top of the windbox. They are designated as OFA (Lower) and OFA (Upper) respectively. The amount of oil firing is designated as % of MCR (maximum continuous rating).

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The other elevations viz., AA, BC & DD house only air nozzles to direct air stream into furnace aiding combustion of fuel. At the inlet of each compartment there are control dampers. Each damper is operated by a damper drive unit. All damper drives in any one elevation receive the same signal from the secondary air control system.

If secondary air admitted to a fuel compartment in service, it is referred as fuel air. Secondary air admitted to the furnace through air compartments and fuel compartments not in service, is termed as auxiliary air.

The auxiliary air damper control is separate from the fuel air damper control.

4.0. CONTROL PHILOSOPHYThe auxiliary air damper control system positions the auxiliary air dampers to maintain a wind box to furnace differential pressure (Refer Figure-2). The auxiliary air dampers are positioned to maintain the required wind box to furnace differential pressure according to the boiler load.

The wind box to furnace differential pressure indicated in Figure-2 is the suggested value to start with during commissioning. In the initial periods of operation, the flame condition with reference to ignition stability, ignition point relative to fuel nozzles, overall combustion conditions in the furnace are to be studied for various wind box to furnace differential pressures and the values are to be optimised at site (the arrow marks indicated in Figure-2 represents that the values are adjustable). Based on this, the final curve showing the relationship between the wind box to furnace differential pressure versus the boiler load is to be decided for the type of coal used. The fuel air damper control system positions the fuel air damper in proportion to the fuel firing rate (Refer Figure-3). The fuel air damper position as indicated in Figure-3 is the suggested value to start with during commissioning. In the initial periods of operation, the flame condition with reference to ignition stability, ignition point relative to fuel nozzles, overall combustion conditions in the furnace are to be studied for various fuel air damper positions and the values are to be optimised at site (the arrow marks indicated in Figure-3 represents that the values are adjustable). Based on this the final curve showing the relationship between the fuel air damper positions versus the fuel feed rate is to be decided for the type of coal used. The final setting must not produce hazardous condition either from Ignition stability or from Ignition point being too close to fuel nozzles in all possible loads, number of pulverisers in service, etc.

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On coal fired boilers the characteristics of fuel like, Fixed Carbon, Volatile Matter and Ash composition will determine the optimum wind box to furnace differential pressures and the fuel air damper positions. Accordingly the optimised settings are to be decided as above for the coal used. Later, if the coal quality changes or the coal source itself is changed, it shall be necessary to once again carryout optimisation studies for the new coal and revised settings are to be finalized. This unit is equipped with oil elevation for warm up and stabilisation (designed for 7.5 – 30 % MCR). In this case the oil elevation dampers are positioned to a fixed % opening during oil firing. When oil is not fired, these dampers are controlled to maintain the wind box to furnace differential pressure in line with other auxiliary dampers.

5.0. OPERATION AUXILLARY AIR DAMPERS :All elevations of the auxiliary air dampers will be automatically switched to “Manual” control and then commanded to open 100%, if any one of the following conditions exist.

�� Both FD fans are Off �� Both ID fans are Off �� Master fuel trip exists �� Loss of Unit +24 V DC supply in FSSS Panel

Also the auxiliary air control loop is tripped to manual if any of the following conditions exist.

�� DP transmitter Deviation High �� Failure of selected DP transmitter �� Furnace to Windbox DP Very High (> 240mm WC) Priority interlocks for selection of auxiliary air control loop to auto is that none of the “Trip to manual” conditions should be present. When the auxiliary air control is placed in the “Auto” mode of operation, the auxiliary air dampers modulate to control wind box to furnace differential pressure at a predetermined set point.

During the furnace purge period and initial operation of the unit up to 30% MCR load all elevations of auxiliary air dampers (AB, BC, CD & DD) modulate to maintain a predetermined set point (approximately 40 mm of water column) differential pressure between furnace & wind box. As the unit loading increases above 30% MCR, the set point ramps up automatically and at a predetermined break point the slope of the ramp changes. The wind box to furnace differential set point is gradually increased as the unit load is increased. Conversely, the differential

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pressure set point is gradually decreased as unit load is decreased. The rate of increase (or decrease) is controlled by the auxiliary damper controller.

Above 30% MCR boiler load, the auxiliary air elevation associated with the main fuel elevation in service, modulate to maintain the varying DP. Those not associated with any elevation in service are closed from top to bottom. The closing signal comes from FSSS.

When the Unit Load is increased above 30% MCR, the Auxiliary air dampers on elevations AB, BC, CD & DD are closed in a timed sequence (10 second interval) provided the associated Coal elevations are not in service and the associated oil elevations are not in service. The auxiliary air dampers are closed, starting from the top elevation, progressing towards the lowest elevation. When the unit load is reduced below 30% MCR, the following events occur :

�� The wind-box to furnace differential pressure set point reverts to its original value �� The auxiliary air dampers associated with the Coal and Oil elevations not in service are

opened in a timed sequence (10 second interval) starting at the lowest elevation, progressing towards the top

When the “Post Trip Purge Time Expired” command is established and “Both FD and ID fans are not off” and “Master fuel trip” command doesn’t exist, then a 35 second counting period is started. After it expires, the “Open All Auxiliary Air Dampers” command is removed from memory. Note :-The End air Compartments present in Elevation-AA have only Dampers at 4 Corners. However, they do not have Drives and Control. These Dampers are adjusted at site and kept at that position, permanently. FUEL AIR DAMPERS : When the main fuel in an elevation, is started, the associated fuel (Coal) air dampers open and modulate as a function of Feeder Speed. A fuel (Coal) elevation is selected to be closed when the associated Feeder is off.

The auxiliary elevation dampers act as fuel (oil) air dampers when oil firing is taking place and is open to a preset position. The fuel (oil) elevation dampers are selected to be closed if there is a back up trip in that elevation and adjacent pulverisers are off and “No Boiler Trip” signal is present. When an Oil Elevation is started (i.e. when the associated “Elevation back-up” trip is removed) the associated auxiliary air dampers in that elevation are set to preset position for Oil firing. The fuel air dampers of all elevations are commanded to open 100% when any one of the following conditions exist.

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�� Both FD fans are Off �� Both ID fans are Off �� Master fuel trip exists �� Loss of Unit +24 V DC supply in FSSS Panel

When a Coal elevation is in service, the associated fuel air dampers modulate as a function of Feeder Speed as indicated by the associated Coal elevation “MODULATING” light coming on. When the Coal elevation is shut down, the associated fuel air dampers are closed, as indicated by a “CLOSED” light.

When the “Post Trip Purge Time Expired” command is established and “Both FD and ID fans are not off” and “Master fuel trip” command doesn’t exist, the “Open upper fuel air dampers (Elevation C, D & both OFA )” command is removed from memory. Thirty seconds later, the “open lower fuel air dampers (Elevation B & A)” command is removed from memory. Fuel (coal) air damper control loop will be tripped to manual if any of the following conditions exist. �� Feeder rate signal failed �� Open fuel air damper command (From FSSS) �� Close fuel air damper command (From FSSS) Priority interlocks for selection of fuel air control loop to auto is that none of the “Trip to manual ” conditions should be present. Whenever a coal elevation is started, the associated fuel air damper control loop is automatically selected to auto mode provided no trip to manual condition is present. OVER FIRE AIR DAMPERS :The over fire air dampers are positioned as a function of the boiler load. (Refer Figure-4). The lower OFA dampers start opening at 50 % boiler load and are fully open when the boiler load reaches 75 %. The upper OFA dampers start opening at 75 % boiler load and are fully open when the boiler load reaches 100 %. The over fire air dampers in two elevations (Lower and Upper) will be automatically switched to “Manual” control and then commanded to open 100%, if any one of the following conditions exist. �� Master fuel trip exists �� Loss of Unit +24 V DC supply in FSSS Panel �� Both FD fans are Off �� Both ID fans are Off �� The wind box to furnace DP exceeds 240 mm WC.

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All open and close commands are generated from FSSS.

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BHATINDA R&M SBC WRITEUP.doc

Bharat Heavy Electricals Limited HIGH PRESSURE BOILER PLANT, TIRUCHIRAPPALLI 620 014.

CONTROLS AND INSTRUMENTATION / FB

CI:4006:SBC/ REV 00 PAGE 01 OF 06

WRITE UP ON SOOT BLOWER CONTROL SYSTEM

PUNJAB STATE ELECTRICITY BOARD GURUNANAK THERMAL POWER STATION (BHATINDA R&M)

2 X 120 MW, UNIT 3&4, CUSTOMER NO: 4006, 4007

Reference drawing numbers1. Scheme of soot blower piping with valves, fittings and instrumentation – 2-00-047-47357 2. Basic scope drawing for SB system – 3-96-185-09451

Rev. No. DATE DESCRIPTION PREPARED CHECKED APPROVED

00 06/08/2007 Initial Release

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I) GENERAL:

Various types of Soot Blowers such as Wall Blowers and Long Retractable Blowers are envisaged for the cleaning of fireside deposits from water walls, Super Heater and Economiser during operation of the boiler. Steam is used as blowing medium in all types of blowers.

II) BLOWERS AND VALVES COMING IN SB SYSTEM

1) Wall Blowers - 40 Nos: + (07 numbers future provision) 2) Long Retractable Blowers - 18 Nos: + (08 numbers future provision) 3) SB steam pressure control valve (pneumatic operated, controlled from SBCP) - 1 No. 4) SB steam Isolation Valve (motorised, open/close command to SBMCC from SBCP) - 1 No. 5) SB drain temp. control valve (24VDC solenoid operated, controlled from SBCP) - 2 Nos.

III) SOOT BLOWER CONTROL PANEL (SBCP)

The SBCP is of Microprocessor based and built by using the Max - DNA hardware. It houses the equipments required for auto sequential operation, remote manual and local operation of soot blower and its valves. The system permits operation of any soot blowers in a sequence and permits omission of any soot blower(s) in a sequence. The blowers can be operated in groups. Only one group programme is operable at a time. The system will permit initiation of any one group programme at a time. Maximum one blower is envisaged to operate at a time in sequence from the same group. The blowers are grouped in different groups as below:-

i) Wall blowers - 1 Group. ii) LR blowers - 1 Group. iii) All blowers - 1 Group.

The Mimic shows the individual SB operating status and the following General / Fault Conditions. Mimic will be prepared in MMI in line with scheme of shoot blowing system valves, fitting and instrumentation. In addition to the scheme, the following indication also will be included in the mimic.

1) AMBER INDICATION TO INDICATE i) 110V AC supply at SBMCC failure ii) Blower over run iii) LR Blower mechanical jamming iv) Blower steam flow low v) Blower motor overloaded vi) Boiler Trip vii) SB Steam Pressure Low viii) Auto Sequence Interrupted ix) Valve Motor overloaded

2) GREEN INDICATION TO INDICATE i) Close SB steam iso. Valve ii) Close SB Drain valve -1 iii) Close SB Drain valve -2

3) RED INDICATION TO INDICATE i) Blower operation (for each blower) ii) Auto sequence ON iii) Open SB steam iso. Valve

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iv) Open SB Drain valve - 1 v) Open SB Drain valve - 2

4) YELLOW INDICATION TO INDICATE i) Auto sequence completed ii) Local start permit iii) All Blower at Home position iv) Blower Forwarding v) Blower Reversing vi) Blower Rotating

IV) SOOT BLOWER CONTROL SYSTEM IS HAVING THE FACILITIES FOR THE FOLLOWING FUNCTIONS: -

1) AUTO/ MANUAL MODE Provision shall be available from MMI for selecting AUTO/ MANUAL operation of soot blowers.

2) LOCAL / REMOTE SELECTION Provision is to be available from MMI for selecting soot blowers for manual operation either from LOCAL or REMOTE (MMI). If ‘LOCAL’ is selected ‘LOCAL SELECTION’ command is issued to SBMCC.

3) START PROGRAMME Provision to be available to start selected operating Programme.

4) STOP Stop command, when issued will stop the auto programme. Operating blower will retract to home position.

5) RESET Reset command, when issued will reset the fault indication, if any. Reset operation is to be made after removing the fault conditions.

6) RETRACT Retract command, can be issued by the operator to a particular blower on any abnormal condition for retracting without waiting blower to complete operation.

7) MANUAL START Any blower can be started manually from MMI, after selecting the blower and giving a manual start command. However, ‘AUTO / MANUAL selection’ has to be selected in manual position before starting the blower.

8) PROGRAMME SELECT Individual automatic blower groups have to be selected before starting the blowers in auto operation.

9) ENABLE/ DISABLE Provisions are available in MMI for enabling / disabling a particular soot blower.

10) SEQUENCE CHECK Indication of selected program sequence to be available in MMI.

11) AUXILIARY CONTROL Soot blowing steam isolating valves and pressure reducing valves is to be operated with the help of push buttons from MMI.

V) SBMCC

The Soot Blower Motor Control Centre consists of power supply ON/OFF Switches for incoming and individual blower/valve motors and Ammeter (A) and Voltmeter (V) with selector switch for incomer.

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Each feeder is equipped with Fuses, Power Contactors for blower Forward/Reverse and Rotary Operation, thermal O/L Relays, aux. Contactors etc.

VI) CHECKS BEFORE STARTING SB OPERATION

1) Put ‘ON' 415V, 3 Ph, AC Incoming Power Supply Switch and control supply transformer switch in SBMCC.

2) Put ‘ON' Individual blower/ Valve feeder Power & Control Supply Switch in SBMCC.

VII) INITIAL CONDITIONS

1) SB Steam iso.valves shall be in closed condition. 2) All the blowers shall be in Home position.

VIII) SOOT BLOWER START PERMISSIVES

1) SB isolation valve opened 2) All blower home position 3) Blower motor not overloaded. 4) LR Blower jamming signal not available. 5) SB steam pressure adequate.

IX) SEQUENTIAL OPERATION

1) Switch on Panel Power Supply. 2) Put Local / Remote selector in Remote position and auto/manual selector in auto position. 3) Select the blowers, which are to be operated through each programme selection. 4) Ensure Initial Conditions 5) Open the respective SB Isolation Valve and allow the steam to drain. Since thermal drain valves

are controlled from SBCP, this will modulate according to the temperature of the line automatically and keep removing condensate, if any.

6) After attaining the required drain temperature & adequate steam pressure, press program start. The first blower will start as per selected programme and the sequence continues. Programme operating display glows to indicate the same. Blower operating indication will be available in MMI.

7) Remote selection and sequence of operation of blowers is possible from CRT/KB in control room desk.

8) Blower’s selection, valves operation and programme start is possible through CRT/KB in control room desk.

9) In sequence start impulse, sequence stop impulse, sequence logic indication, individual blowers operation in a group and the mimic display for the same are to be executed through CRT/KB by the operator in control room.

X) BLOWER OPERATION

1) WALL BLOWER: - As soon as the start impulse is given, the traverse motor of Wall blower gets supply and the blower moves forward. The red lamp in mimic glows to indicate the operation of that blower. The yellow lamp for indication of ‘Blower Forward’ also glows. When the blower reaches its forward end position the traverse motor trips and the rotary motor gets supply and rotates the lance. The yellow lamp for ‘Blower rotating’ glows. Simultaneously steam valve will open and allows the steam for blowing. When the lance completes one rotation the rotary motor trips, traverse motor

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gets supply and the blower retracts. The yellow lamp glows to indicate ‘Blower Reversing'. When the blower reaches home position the mimic lamp goes off. Now the next blower in the sequence gets the pulse and start operating.

2) LONG RETRACTABLE BLOWER When the Long Retractable blower gets the pulse, first the rotary motor starts rotating. The ‘NO' contact of contactor ‘CRO' for rotary motor closes and the traverse motor starts and holds through limit switch LS-2 contact. The blower moves forward. The Red lamp in mimic glows to indicate blower operation. Yellow indication lamps for ‘Blower Forward' & ‘Blower rotating’ glows. When the blower reaches the forward end position, it actuates Limit switch LS1 which stops forward motion of the blower. Immediately the blower reverses. The yellow lamp for ‘Blower Retracting' glows. As soon as it comes back to home position, both traverse and rotary motors are stopped and lamps in mimic goes off.

When any fault activate, the operating LR/WB blower retract automatically to the home position. The sequence will be stopped and reset light flashed. The sequence can be continued after removing the fault and resetting the controller.

Fault conditions are listed below: -� Blower motor overloaded. � LR Blower jamming (appl. for LR blower only) � SB steam pressure low. � Remote retract signal from SBCP. � SB steam flow not adequate after 3 seconds from the following conditions: -

� Blower start for LR blower � Blower rotating for wall blower

When all the blowers complete operation, as sequenced in programme an indication lamp will glow to indicate “Sequence Completed” condition.

SB steam main isolation valve: - i) The SB motorised isolation valve shall be closed automatically when the control valve is

opened less than 2% and vice versa.

XI) MANUAL OPERATION FROM PANEL1) Select Local / Remote selection for Blowers / Valves in remote and auto/ manual to manual. 2) Select the blower to be operated and give manual start command. 3) The selected blower operates and completes its operation and comes back to the home position.

The respective blower operating lamp in mimic, Blower Forward / Reverse /Rotary indication comes as in the case of sequential operation.

XII) MANUAL OPERATION FROM LOCAL1) Select the Local / Remote Selector for blower and valves in local position and auto/ manual to

manual. 2) The operator at field can operate any one blower by using Local Start / Retract Push Button Box. 3) The selected blower operates and completes its operation and comes back to the home position.

The respective blower operating lamp in mimic, Blower Forward / Reverse /Rotary indication comes as in the case of remote operation. Operator from field cannot operate other blowers until the blower comes back to home position.

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XIII) GENERAL1) During sequential operation / remote manual, the operating blower can be retracted by pressing

the Retract Push Button. 2) The sequence can be stopped at any time by using the Stop Push Button. 3) Any blower can be bypassed by selecting blower and pressing disable push button.

XIV) NOTE:-1) At a time, only one blower can be operated. 2) CRT/KEY BOARDS ARE common for FSSS, SBC & SADC System. 3) SB operation can be made through CRT/KEY BOARD. 4) SB mimic diagram will be implemented in MMI as per “Scheme of soot blowing with valves,

fittings and instrumentation”

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BHELVISION 20 M

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BHELVISION 20 M

ELECTRONIC WATER LEVEL INDICATOR

Installation & Maintenace Mannual (Version II) PUNJAB STATE ELECTRICITY BOARD GURUNANAK THERMAL POWER STATION BHATINDA R&M, 2 x 120 MW UNITS -3&4.

DANGEROUS VOLTAGES ARE PRESENT IN THIS EQUIPMENT. GREAT CARE SHOULD BE EXCERCISED WHEN SERVICING THE EQUIPMENT AND ANY WARNING NOTICES OR PROCEDURES CONTINUED IN THIS MANUAL OR ON THE EQUIPMENT SHOULD BE STRICTLY OBSERVED

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BHELVISION 20 M ELECTRONIC WATER LEVEL INDICATOR

Installation manual (Version II)

CONTENTS

Section 0 Do’s and Don’ts Section 1 Introduction Section 2 Installation Section 3 Maintenance Section 4 Troubleshooting Section 5 Installation/part drawings Section 6 Specifications Section 7 Checklists Section 0 – Do’s & Don’ts

Do Switch off power supply before replacing any module.

Don’t Keep the cabinet door open.

Do Ensure proper connector seating and screws fixed at top & bottom of rack after inserting any module.

Don’t Use a blower for cleaning the panel.

Do Follow jumpering guide before inserting any module.

Don’t Attempt field servicing. Return faulty module to BHEL (T) for servicing.

Do Return faulty module to BHEL Trichy for servicing

- -

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Section 1 – Introduction

1.0 General

The BHELVISION 20M Electronic Drum Water Level Indicator is Conductivity based water level sensing system for reliable level monitoring used in High pressure applications like steam boiler drums.

Traditional Visual Gauges & Differential Pressure Manometer Gauges used for Boiler Drum water level sensing suffer from the inherent measuring errors due to density difference. In addition, they require constant attention & maintenance.

BHELVISION 20 M operates on the principle of discrimination between the differing resistivities of Steam and Water at high pressure and temperature.

1.1 Salient Features

An automatic choice for critical applications like boiler drum water level sensing, BHELVISION 20 M is designed with features to cater

� Easy Installation � Low & Easy Maintenance � High Accuracy � Reliability� Built-in Fail safe features � Built-in Fail operative features

1.2 Main components

BHELVISION 20M system consists of following major sub-systems:

� Pressure Vessel & Accessories � Electrode Probe � Ascertor Cabinet & Electronic

modules � Displays

The system arrangement showing the above components are given below:

Fig. 1.1.1 SYSTEM ARRANGEMENT

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1.2.1 Pressure Vessel & accessories

BODY VESSEL:

The pressure vessel is made up of SA105 material of thickness 115 mm. The design, fabrication and inspection of vessel will be as per IBR. The body vessel is designed for 207 Kg/Sq.cm pressure and 368 Deg.C temperature. The hydraulic test pressure for vessel is 310.5 Ks/Sq.cm. The major items for body vessel are Body, flat end cover, stub, vent / drain nipple, lifting lug, clamping plate and guard assembly. The electrode pitch is 50mm apart. Normal water level marking is provided on the vessel. A typical pressure vessel is shown in Fig 1.2.1

ELECTRODE:

The electrode as shown in fig 1.2.2 consists of several sub items. To meet the specified service, the raw material is sourced carefully. The electrode body, electrode tip, body insulant & center stud are important items of an electrode. The electrode body is manufactured from martensitic stainless steel to Firth Vickers specification FV520 (B) /SA276 type 410 which has good resistance to stress corrosion and low coefficient of expansion. The center stud is manufactured from IMI titanium so that the coefficient of expansion closely matches that of electrode body. The brazing is carried out with special brazing foil in closely controlled vacuum furnace. The spiral wound SS316L graphoil filled sealing gasket is used with the electrode.

1.2.2Steam / Water tapping and Isolation valves

Each Water and Steam connections are provided with 2 Nos. of Isolation vales to isolate the Body vessel. 2 Nos. Vent and Drain valves are also provided for each body vessel. The pressure and temperature rating of these valves are same as that of drum design rating. The valves are made of carbon steel material SA105.

Fig.1.2.1 PRESSURE VESSEL

Fig.1.2.2 ELECTRODE

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1.2.3 Ascertor Cabinet

The ascertor cabinet Consist of following modules and components mounting in a cabinet for 250 MW & and below rating boilers. Normally two ascertor cabinets (1 per side) are provided. The OGA of ascertor cabinet is shown in fig.1.2.3. A typical component layout arrangement of system is shown in Fig. 1.2.4 LAYOUT OF COMPONENTS

Ascertor cabinet houses the following modules and components: a) Ascertor module (AS2018) configured for 6 ports

2 Nos.

b) Display driver module (DD2018) configured for 12 ports

2 Nos.

c) Relay driver module configured for the required Lo alarm Lo trip setting

1 No.

d) Micro controller module (MC2018) configured for 8 ports

1 No.

e) Linear Power Supply for 230V AC

2 Nos.

f) System mother board (MB2018)

1 No.

g) Power supply mother board

1 No.

h) Required electrical components like MCBs, TBs etc are assembled and duly wired.

Fig. 1.2.3 OGA OF ASCERTOR CABINET

Fig. 1.2.4 LAYOUT OF COMPONENTS

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1.3 Ascertor Module AS 2018

� Six channels per module � Multilevel comparators for

fault diagnostics � Relays for auto simulation

1.3.1 AS2018 Operation The oscillator circuit generates & feeds an AC square wave signal of 50 Hz (approx) frequency to the electrodes. Signal output from electrode varies depending on the resistivity of medium that surrounds it (water or steam) in the pressure vessel. This output is precision rectified and compared with a preset-reference to determine the medium.

Presence of water is ascertained if the electrode resistance falls below 100 k�(approx.). Presence of steam is ascertained only when electrode resistance rises greater than 200 k�(approx.).

Between water and steam status, a hysterisis band of 100 k�(approx) accommodates the changes in medium resistance due to process variation in Pressure, Temperature, Conductivity, pH, etc.

This adjustment is factory set and not recommended to change at site

The AS2018 is powered from the motherboard with 12 V DC. All Input/Output connections are through motherboard.

Fig 1.3.1 ASCERTOR MODULE

Fig 1.3.2 AS2018 – BLOCK

SCHEMATIC

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1.3.3 AS2018 Function blocks

AS2018 has six channels per module and may be programmed to select two to six channels by appropriately setting the jumpers.(See Jumper Guide)

Each AS2018 provides excitation voltage through a biasing network for six Electrodes. The intelligence from these electrodes are further processed to indicate water / steam. Each individual channel consists of the following:

� Precision rectifier � Filter� Multi-level Comparator

Precision rectifier and filter process the signal output from the electrode. The rectified filtered signal is then fed to the comparator

Each comparator has a Threshold and Hysterisis. The comparator monitors the signal level and depending on the values of the electrode resistance encountered, it provides logical 0 or logical 1 output, corresponding to steam or water status

All the water and steam information from this module are communicated through a common bus structure on the motherboard printed circuit to all other modules.

1.3.4 AS2018 Features

Another comparator detects any Open / short fault condition of cable / Electrodes. When a fault is detected,

‘Electrode fault’ signal is generated for further processing

A watchdog circuit generates ‘AC excitation failure fault’ (Clock fault) in case of oscillator failure.

Auto simulation drivers (Miniature relays) are present which facilitate the check of system healthiness for steam / water status, when simulated from Micro controller module - MC2018 by pressing the test button provided in the remote display unit at UCB.

Fig 1.3.3 AS2018 – JUMPER

SETTINGS 1.3.5 AS2018 – Jumper configuration The AS2018 module has two sets of four jumpers for selecting output signals and fault signals of individual channel.

The normal configuration of these berg-stick jumpers is shown in fig 1.3.3Note that the jumper settings are slot dependent. The appropriate jumper configuration of AS2018 modules must be ensured slot wise before powering up the system.

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1.4 Display Driver Module DD 2018

� Single module for two displays � No separate power source

required for displays � In-built protection circuit � User settable channel

selection

1.4.1 DD2018 Operation

Ref. Fig. 1.4.2 DD2018 for block schematics. This module serves as buffer and current driver for driving the display units. Each module can cater to two display units.

The Display driver DD2018 is powered from the motherboard with 12V DC. Power to the display units is derived from this module. This power supply is protected against short circuit by a current fold back circuitry.

All input/output connections are through the motherboard. The DD2018 drives display LEDs - Red/Green/Yellow at LOCAL and display units located at UCB based on Water / Steam / Fault information from the status bus.

One module caters to two display units with a maximum of 18 ports. The number of output drives selected through jumpers can be 8, 10,12,14, 16 and 18.

Fig 1.4.1 DISPLAY DRIVER MODULE

Fig 1.4.2 DD2018 – BLOCK

SCHEMATIC Note: Jumper setting is to be ensured before powering up.

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1.4.2 DD2018 Jumper Setting The DD2018 module has ten jumpers (J1 to J10) for selecting number of display channels.

The normal configuration of these berg-stick jumpers are shown in fig 1.4.3

Fig 1.4.3 DD2018 JUMPER SETTINGS

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1.5 Relay Driver Module RD 2018

� Drives trip & alarm contacts � Individual displays for trip &

alarms� 2 out of 3 voting for trip

generation� Fault annunciation displays

1.5.1 RD2018 Operation

RD2018 receives the STEAM / WATER signals from the Ascertor through the status bus.

This module provides following contact outputs.

� Water level very high� Water level very low � For initiating trips and alarms

The Relay driver RD2018 is powered from motherboard with +12V DC. All Input / Output connections are through motherboard. It houses seven relays.

1.5.2 RD2018 Features

RD2018 may be configured for the required Hi/Lo alarm setting.

Contacts are also given for� System fault � Electrode fault and� Trip disable.

Trip relay is actuated if any two channels vote for trip. i.e. if Nth port is connected to trip, then N+1 and N-1 ports are also considered for voting.

Fig.1.5.1 RELAY DRIVER MODULE

Fig 1.5.2 RD2018 – BLOCK

SCHEMATIC LED indications are provided in the

fascia plate for � High Trip � Low Trip� High Alarm � Low Alarm� System Fault � Electrode Fault

In case of System fault, steady output is given to energies fault LED In display units whereas the same flashes in case of Electrode fault.

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System Fault consists of

� Any power supply failure

� Absence of any module

� Excitation ac failure

� Validation fault

Electrode Fault consists of

� Electrode, cable open circuit

� Electrode short circuit

NOTE: Since probe fault detection is also based on the measurement of input resistance, this detection will be effective only after the water in the drum crosses a specified pressure / temperature, depending on the actual site condition like conductivity of water etc., Hence during initial boiler start up. Probe fault LED of this module may light up (and the fault LED in the display unit may flash) which will not affect any other function like steam / water detection, alarm / trip function etc., This fault indication will vanish automatically after a specified temperature / pressure at the drum is reached. In view of this, fault indication may be ignored during boiler start-up operation. Normally probe fault detection facility is not recommended. If needed this facility may be by-passed by suitable jumper connection in ascertor (AS2018) modules. A manual lockable switch is given on the fascia to Enable / Disable the trip (Low & High) functions as and when required during maintenance, testing etc.

The key can be released / removed only in the trip enabled mode. When

a disable mode is selected then the trip driver logic output is kept isolated and trip relays will be at ”No Trip“ condition. 1.5.3 RD2018 Trip & Alarm Voting 2 out of 3 logic is used to initiate a trip signal. If Nth (Maximum port number can be 16 -1 say 15) port is opted for High Trip then (N-1), N & (N+1) known as Steam ports have to be selected through jumpers.

Similarly if nth (Minimum port number can be 1+1 say 2) port is opted for Low Trip then (n-1), n & (n+1) known as Water ports have to be selected through jumpers.

When the water in the pressure vessel reaches the steam ports and any two steam ports vote for presence of water then a High Trip is generated with a time delay.

Similarly when the steam in the pressure vessel reaches the water ports and any two water ports vote for presence of steam then a Low Trip is generated with time delay

Alarm initiation is similar to Trip, except 2 out of 3 logic and without time delay. The port (range) selectable for Low & High alarms is between 2 & 12, selected through jumpers.

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1.5.3 RD2018 Facia Indication 1.5.4 RD2018 – Alarm & Trip Values

High Trip +175 mm from NWL

Low Trip -175 mm from NWL

High Alarm +125 mm from NWL

Low alarm -125 mm from NWL

1.5.5 RD2018 – Jumper setting

The Alarm and trip values are set in the RD2018 module at the manufacturers’ works. The settings are permanently soldered jumper configurations as per the contract requirement and should not be disturbed at Site under any circumstances.

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1.6 Microcontroller Module MC 2018

� State-of-art architecture

� Input signal validation

� In-built logic for fault detection

� RS 232 interface to DDC MIS

1.6.1 MC2018 OperationThe Micro controller MC2018 is powered from motherboard with +12V DC. All Input / Output connections are through motherboard. MC2018 may be programmed for channels viz. 8 / 10 / 12 / 14 / 16 / 18 with jumper connection. This module does validation checks on the Electrode inputs. This module gives 4 – 20 mA DC current output corresponding to water level. Water above steam and steam below water are invalid conditions, which are detected by this module. In such case the current output is forced to 4 mA level. Once the fault is cleared, the current output will automatically go to the value determined by the level of water.RS 232 C outputs are also generated, which gives information on level of water, trip / alarm status etc. This output can be used to interface with DDCMIS. Auto simulation signal is generated to drive the relay drivers housed in the AS2018 modules.

Watch dog timer circuit interrogates the CPU at regular intervals and flashes the ‘CPU OK’ LED in the front facia. This LED will be off, if CPU failure occurs.

Fig. 1.6.1 MICROCONTROLLER MODULE

Fig 1.6.2 MC 2018 – BLOCK

SCHEMATIC

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4006 & 4007 VOL D1 TAB-5-259

BHELVISION 20 M


1.6.2 MC 2018 – Jumper setting

MC2018 may be configured for channels viz. 8 / 10 / 12 / 14 / 16 / 18 with jumper connection.

The normal configuration of these berg-stick jumpers are shown in fig 1.6.3.

Jumper configuration of this module must be ensured before powering up the system.

Fig 1.6.3 MC 2018 – JUMPER SETTINGS

2091445B

4006 & 4007 VOL D1 TAB-5-260

BHELVISION 20 M


1.7 Power supply Module PS 2018

� Input 230V AC +/- 10 %

� 12 V DC regulated output

� Redundant failsafe configuration

� Auto-changeover feature

1.7.1 PS2018 Operation

This Module generate 12 V DC regulated output. This regulated output feeds power to all the modules. Two such modules are used for redundancy, so that even if one power supply fails, other power supply takes over automatically & instantaneously, through Auctioneering diodes provided in Power supply motherboard. Input power supply is connected to terminals provided in the power supply motherboard. Regulated +12 V DC output is fed to the system motherboard for feeding power to various functional modules.

These modular power supplies are designed to mount in a standard 19th single euro rack in the form of a plug in power supply. The AC mains input and DC outputs are provided on H15 rack connector for easy insertion of the power supply unit in the rack. The power supplies are fully enclosed with sufficient ventilation cutouts so that colling can take place with natural convection method. These power supplies are designed using approved components for highest reliability.

These power supplies are designed with appropriate de-rating of the components operating conditions so that the power supplies can still function satisfactorily. None of the component used in the module will be proprietary in nature.

Regulated +12 V DC output is fed to system motherboard by these modules for feeding power to various functional modules.

Fig.1.7.1 BLOCK SCHEMATIC OF LINEAR POWER SUPPLY

Fig.1.7.2 FRONT VIEW OF PS

2091445B

4006 & 4007 VOL D1 TAB-5-261

BHELVISION 20 M


1.8 Display Unit

� Coloured LED displays for steam/water level status

� Individual display units for Local, operating floor & remote indication

� Test/Simulation facility for system check

� Compact & rugged display unit

1.8.1 Display unit Operation

The Display unit is provided with a parallel array of Red and Green LEDs (12 pair of LEDs) and 1 Yellow LED arranged at the panel front.

The number of glowing LED pair is equal to the number of electrodes.

One such display unit is fixed on the Ascertor Panel door itself for local viewing and one more display unit is supplied for mounting at UCB for each end of the drum, for the Indication system. One No. Display unit for operating floor indication is also provided. The power supply and the drive for this unit come from display driver module.1.8.2 Display unit Test Simulation By momentarily pressing the ‘Test’ push button is given in this unit, one can quickly check the functioning of the equipment, on line.

During this self-test period, all the channels are given a simulated input

Fig. 1.8.1 DISPLAY UNIT(Typical) corresponding to water for one second and all green LEDs should glow now.Immediately next, all simulated inputs are changed to steam so that green LEDs should switch off and now all red LEDs should glow for one second. During this period of 2 seconds test simulation TEST LED glows.During this test simulation period, trip status corresponding to pre test period is maintained. However, alarm status is not maintained. By this arrangement, on line simulation testing of BHELVISION-20M system from UCB is made possible. Normally, test simulation button in Ascertor display is kept disconnected. This facility is made available only in UCB display.

2091445B

4006 & 4007 VOL D1 TAB-5-262

BHELVISION 20 M


Section 2 – Installation

2.0 General

The installation procedure comprises the following activities

� Pressure vessel erection � Ascertor cabinet installation � Display unit installation � Cabling & Termination � Electrode installation

2.1 Pressure vessel installation

Each vessel is delivered with four isolation valves and two Drain / Vent Valves. All 12 electrode ports have blanking plugs fitted that should not be removed until later, when the electrodes are fitted. The Pressure Vessel is delivered complete with 12 electrodes and 12 Metaflex gaskets. These are fitted immediately prior to electrical pre-commissioning. It is essential that electrodes are NOT fitted until acid and steam purging has been completed. The Pressure Vessel is provided with lifting eyes at its upper end to support its weight from the superstructure.

Fig.2.1.1 PRESSURE VESSEL INSTALLATION

2091445B

4006 & 4007 VOL D1 TAB-5-263

BHELVISION 20 M


2.1.1 Pre-erection checklist Before drawing the Pressure Vessel from store the following points must be checked.

� Ensure that access to work on this part of the plant is clear

� Ensure vessel Isolating Valves have been fitted to the steam and Water connections on the Drum and are ready to have the Pressure Vessel welded to them.

� Check hardware required for supporting the pressure vessel are available.

� Ensure the location of suspention points on the super structure has been firmly supported as per site requirement.

� It should be noted that all joints in pipe work must be welded, tested and inspected in accordance with the standard welding procedure.

2.1.2 Vessel checklist Notify the unit operator of the intention to commission the vessel, in accordance with recognised procedures.

� Check that the electrode guard is in place.

� Close drain & vent valves. � Open water and steam isolating

valves nearest to boiler drum. � Crack opens the isolating steam

valve nearest to the pressure vessel. Check with the unit operator that the vessel slowly fills with condensate (about 10 -15 minutes).

� Crack opens the isolating water valve nearest to the pressure vessel. Check with unit operator that the water level is falling to approximately normal water level.

2.1.3 Vessel installation

The steam and water connections on the Pressure Vessel have to be aligned in the vertical plane with the steam and water connections provided on the Boiler Drum ends and welded to those connections. The Steam and Water connections on the drum have been set to position the Pressure Vessel at the correct level when they are welded in place. However, due to the length of the connecting pipe work, these could be offset and care must be exercised to ensure that they are not allowed to take the unsupported weight of the vessel. Bearing this in mind, installation should commence with the attachment of the vessel supports to the superstructure. The Pressure Vessel may then be attached to the supports that will carry the weight of the vessel and allow it to be accurately aligned with the drum steam and water connections before and during the welding operation. After welding to the connecting pipe work and fitting drainpipe work is complete, a further check for level should be carried out and adjustments made, if necessary. NOTE: The water connection to the Pressure Vessel must be lagged. The steam connection should NOT be lagged within the last 1.5m from the Pressure Vessel. The body of the Pressure Vessel itself must NOT be lagged.

When the installation of the Pressure Vessel has been completed, precautions must be taken to protect it against damage during the installation of adjacent plant equipment / pipe work etc.

2091445B

4006 & 4007 VOL D1 TAB-5-264

BHELVISION 20 M


2.2.1 Pre-installation checklist

Before drawing Ascertor Cabinet from store, the following points should be checked:

� The exact position for installation has been determined.

� Access to work on that part of the plant is clear.

� Lifting tackle and adequate suitable layout are available to raise the unit to its position at Drum Level.

2.2 Ascertor cabinet installation

The Ascertor Cabinet is to be sited at Drum Level. Ensure by examining the internals that the correct unit is drawn from store that it is undamaged and in a suitable condition for installation to start. The unit is to be wired to the Pressure Vessel and is to be positioned so that the length of cabling connecting it to its Pressure Vessel does not exceed 15 meters (appx).

The Ascertor Cabinet is provided with fixing holes in the rear vertical face for bolting it to the wall or suitable support structure. Transport Ascertor Cabinet to location. Bolt and position carefully on prepared surface. Fix using bolts, nuts and washers or equivalent fastenings. When the unit has been positioned and bolted in place, adequate precautions must be taken to ensure that it is protected against accidental damage during the installation of adjacent plant / equipment and pipe work or the completion of any local building work.

2.3 Display installation

The installation of the Display Unit in the Central Control Room will be carried out by other contractors, along with other UCR equipment as and when required. The display cutout details are provided on OGA of display unit drawing.

The method of fitting is as follows: � Remove top and bottom

clamping plates by removing holding screws.

� Insert the display to the cut out hole in Control Room Desk or Panel.

� Re-fit the clamping plates, making certain that they hold the display rigidly to the Control Desk or Panel.

� Connect cable to appropriate connections.

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4006 & 4007 VOL D1 TAB-5-265

BHELVISION 20 M


2.4 Cabling

The external connection Drawing shows details of connections between the Pressure Vessel and Ascertor Cabinet at the Boiler Drum level.

This wiring is to be carried out using P.T.F.E insulated, 10 pair 0.6 sq.mm special cable supplied with the system.These are terminated, at the electrode end with crimp-ring terminals and at the Ascertor Cabinet end with crimp pins. The conductors should be identified with suitably marked ferrules at each end.

The cables from each electrode of the Pressure Vessel must be grouped together and laced with heat resistant lacing thread, or tie wraps, to form a loom throughout their length.

The loom must be securely cleated where it leaves the vessel and shall be supported by and cleated to the perforated cable tray throughout its length to the Ascertor Cabinet.

The cables from the vessels, where it enters the base of the Ascertor Cabinet, must pass through glands provided. The wiring within the Cabinet is run neatly and terminated as prescribed above (crimp pins).

2.5 Pre-commissioning checkWhen all the installation and cabling work called for in this specification has been completed, the

commissioning engineer must be advised so that arrangements may be made for him to inspect the installation prior to pre-commissioning tests being carried out after the electrodes have been fitted under his supervision.

2.6 Electrode assemblyElectrode assembly should be

carried out immediately prior to the electrical pre-commissioning of the complete system.This consists of removing specified blanking plugs and Metaflex gaskets and replacing them with the electrodes and new Metaflex gaskets.Before starting on this work, the following points must be checked:

� Ensure that access to work on this part of the plant is clear and that the Pressure Vessel has been fitted and is ready to be worked on.

� Check that hydraulic testing, acid cleaning and steam purging have been carried out.

� The Vessel Isolating Valves must be CLOSED and the drain / vent valves OPENED.

NOTE: - A suitable M18/M19 socket spanner is required for removal of the blanking plugs and fitting of the electrodes. This must be fitted with an extension to clear the electrical terminal end at the top of the electrode being fitted.The electrode positions on the vessel are protected by two hinged guards, which must be opened to gain access to the electrodes. Each electrode or blanking plug is held in the wall of the vessel by a clamping plate, which is secured by four M19 studs, nuts, and washers.

2091445B

4006 & 4007 VOL D1 TAB-5-266

BHELVISION 20 M


2.6 Electrode assembly (contd.,)

When the nuts are removed, the clamping plate, blanking plug and Metaflex gasket may be withdrawn. The blanking plug and old Metaflex gasket must be discarded and replaced by the electrode and a new Metaflex gasket. The clamping plate and four washers are then replaced and the nuts assembled finger tight. Using the socket spanner, tighten the nuts progressively, a quarter turn each, until there is NO gap visible anywhere between the inside face of the Clamping Plate and the machined face of the Pressure Vessel. Care must be exercised to prevent damage to the electrode when tightening the nuts, THE MAXIMUM torque to be applied to the nuts in order to close the gap referred to be 110 Nm (80lb ft). Normally 70Nm (50lb ft) is sufficient. Refer to the instruction sheet issued with each electrode. Care should be taken when attaching the prepared PFTE cable ends to avoid mechanical damage to the electrode.

NOTE: For scope and size of cable, refer “Scope And Cabling Diagram”

Fig.2.6.1 Electrode Assembly

2091445B

4006 & 4007 VOL D1 TAB-5-267

BHELVISION 20 M


2.7 Commissioning checklist

SYSTEM DETAILS

CHECK / TEST / OBSERVATION

STATUS

COMMENTS / RECORD

COMPLETE SYSTEM

Installation Visually Correct

ELECTRONICS & CABLES

System Cabling and Termination

WATER COLUMN

Verification against Drum NWL. (e.g. Clear Plastic Tube filled with coloured water)

POWER SUPPLY

Ensure power supply fuses are removed. Check for correct voltage and fuse ratings before installing fuses and switching power on.

SYSTEMTESTSDISPLAY’S

Connect Bhelvision electrode simulator (at Ascertor Panel) switch all Ports to STEAM.

WATER INDICATION

Starting at Port 1, switch each Port to water until ALL WATER is shown; At each Port verify correct indication of level at Local, UCB & operating floor displays.

STEAM INDICATION

Starting from Port 10, switch each Port to steam until ALL STEAM is shown. At each Port verify correct indication of level at Local and UCB displays.

2091445B

4006 & 4007 VOL D1 TAB-5-268

BHELVISION 20 M


2.7 Commissioning checklist (contd.,) SYSTEM DETAILS


STATUS

COMMENTS / RECORD

FAULT ALARM

Switch Ports to ALL STEAM Starting from Port 2, switch each Port to water to introduce a “WATER ABOVE STEAM” condition to induce the FAULT ALARM. Normalize each Port to steam to clear alarm before proceeding to next Port. At each Port, check relay fault output terminals for correct contact state.

LOW LEVEL ALARM

Switch Ports to indicate 50% water level (Typical NWL). Starting from the top of the indicated water level, switch each port to STEAM until the LOW LEVEL ALARM relay acts. Note Port & contact state in alarm condition.

LOW LEVEL TRIP

Continue to switch Ports to STEAM until the LOW LEVEL TRIP relay acts. Note Port & contact state in Trip condition.

HIGH LEVEL ALARAM

Switch Ports to indicate 50% water level. (Typical NWL). Continue to switch ports to WATER until the HIGH LEVEL ALARM relay acts. Note Port & contacts state in Trip condition.

HIGH LEVEL TRIP

Continue to switch Ports to WATER until the HIGH LEVEL TRIP relay acts. Note Port & contact state in Trip condition.

ANALOG OUTPUTS

Switch Ports to ALL STEAM Check output is 4mA.

2091445B

4006 & 4007 VOL D1 TAB-5-269

BHELVISION 20 M


2.7 Commissioning checklist ( contd.,)

SYSTEMDETAILS


STATUS

COMMENTS / RECORD

Switch Ports 1 to 3 to indicate water. (25 % water level) Check output is 8mA.

ANALOG OUTPUTS



Switch Ports to ALL WATER. (100 % water level) Check output is 20mA.

Switch Ports to ALL WATER. Simulate Water above Steam condition (Validation fault) Check output is 4mA.

2091445B

4006 & 4007 VOL D1 TAB-5-270

BHELVISION 20 M


Section 3 – Maintenance

3.0 General

So for as the valves and pipe work to the pressure vessels are concerned both regular maintenance and repair work should follow existing site practice. No regular maintenance on the vessels, or electrodes is required, except as detailed below.

3.1 Required Tools Tool Purpose

Torquewrench

To tight clamping plate

Simulator To simulate Steam/ water condition of the port

GasketRemover

To remove gasket

Face Cutter To repair damaged electrode gears

3.2 Daily Check list

� Visual Check for steam leaks at the vessel

� Visual check for damage to electrodes

� Visual check for indication in Display units at UCR, Firing floor & drum

3.3 Monthly check list Pressure vessel

� Check the WATER pipe lagging is secure

� Check Vessels & STEAM pipes are NOT lagged.

� Blow or brush off gently any large accumulations of pulverized fuel dust or fly ash on the external insulators of the electrodes.

� Check that electrode connections are tight and the leads are intact.

Ascertor Cabinet

� Check all cabling for secured connection.

� Check all modules are in its position.

� Check operation of relays � Check local & operating floor

displays

3.4 Annual overhaul

To avoid mechanical damage to the vessels, electrodes and electrode wiring due to other work, which may be required at drum level, should be protected by temporary shielding. The vessels should be drained, but need not be isolated from the cold empty drum.

2091445B

4006 & 4007 VOL D1 TAB-5-271

BHELVISION 20 M


After other works has been completed and the temporary protection removed, check that no visible damage has occurred to electrodes and leads, and that the electrode connections are tight and free of dust.

The drains should be closed and the isolation valves left open immediately before the hydraulic pressure test on the drum, so that the vessels with their electrodes can be included in this test.

Any electrodes showing signs of leakage should be replaced immediately after this test, the vessels should again be drained until required for service (this is to prevent the accumulation of sludge in the vessels).

3.4.1 Pressure parts

With any water/steam detection gauge, even a very small leak anywhere on the detection device or its connections will cause error, as also can a partial blockage. Except for an extremely severe leak either a leak or blockage, whether on the steam or the water side of the device or its connections, will cause the detector to give incorrect readings.

It should be noted that the (EWLI) BHELVISION pressure vessel thermal design is such that density errors in water level indication (due to pressure vessel water columns being at a lower temperature than boiler drum water temperature) are

reduced to less than 25mm for the temperatures and pressures specified.

This is achieved by stimulating condensate (by omitting lagging on the vessel steam pipe flow in the upper part of the vessel) the heat thus released is conducted to the water column in the lower part of the vessel.

The flow of condensate itself also maintains the temperature of the water column.

3.4.2 Electrode & Seal Leaks

The distinction between seal and electrode leaks is often difficult to determine prior to removal of the electrode, unless the leak is small.

Steam wisps which appear to emanate between the outside of the electrode body and the bore of the gland clamping plate are indicative of a seal leak, whereas steam appearing through the external ceramic insulator (which is only a spacer and is not intended to be pressure resistant) suggests that the electrode itself is faulty.

Even if the electrode is in water, the water temperature in an operating detection device will cause the water to flash off to steam as atmosphere is reached.

2091445B

4006 & 4007 VOL D1 TAB-5-272

BHELVISION 20 M


3.4.2 Electrode & Seal Leaks (contd.,) DO NOT attempt to cure a seal leak by over tightening the gland clamping plate nuts.

The base of the gland clamping plate seats on to a land in the vessel itself and the most probable fault lies in damage to the Metaflex sealing washer. The correct degree of compression on this washer is inherent in the depth of the recess below the land, which accepts the washer with the gland clamping plate seated on the land.Tightening beyond this point will only cause damage to the studs or the nuts.

The correct procedure for repairing either a seal or a failed electrode is to isolate and drain the vessel.Remove the electrode lead and the knurled nut completely from the electrode, remove the gland clamping plate and remove the electrode complete with its sealing washer.

Examination of these items may give a more positive identification of the cause of the leak. Unless it can definitely established however, that the electrode was not the cause, it is advisable to fit a new electrode at this stage.To assist in identification, a seal leak may be cause either by:

� Incorrect centering of the sealing washer on the electrode prior to its insertion in the vessel, so that it catches on the edge of the land and is distorted by

subsequent tightening of the clamping plate nuts, even if in the process it eventually enters the recess.

� Failure on a previous occasion to remove the old washer or all the broken parts thereof, from the recess before inserting the prevent washer and electrode.

� Re using an old and already previously compressed washer instead of a new one.

� Failing to ensure that the land and the recess were clean and undistorted.

Before reinserting an electrode, check that an old washer or part of has not been wedged in the recess and that the land is not obstructed. A small Electrode with an L shaped pointed end, could be used to dislodge it by hooking the pointed end into the v - shaped groove in the gasket, NOT between the gasket and the seat. In addition, check that the gland clamping plate and studs are not distorted. If a serious “blow” occurs, immediate attention is required. Ensure that the vessel is ISOLATED AS SOON AS POSSIBLE (at least within a few hours), otherwise electrode port seat erosion may necessitate removal of the vessel. Site machining of the pressure vessel is possible and satisfactory results are usually obtained; however, it is more difficult to determine accurately the depth of the cut.

When a seat is cut, the corresponding amount of metal must be removed from the face of the clamping plate flange to ensure that the gasket is correctly compressed.

2091445B

4006 & 4007 VOL D1 TAB-5-273

BHELVISION 20 M


3.5 Safety Precautions

� PROCEED ONLY WITH A VALID ‘PERMIT TO WORK’

� Ensure that tripping is disabled and that operators expect erroneous indications or alarms.

� Ensure that you know the valve positions and other procedures BEFORE working on the pressure vessel.

� Wear industrial gloves to change electrodes.

� Replace convention chimney electrode covers before pressurising vessel.

3.6 Vessel IsolationAfter obtaining authority to isolate the vessel:

� Close off the steam and water isolating valves nearest to pressure vessel.

� Close off the steam and water isolating valves nearest to boiler drum.

� Open drain & vent valves and proceed with work required.

3.7 Electrode replacement

There is no need to switch off the EWLI - BHELVISION electronic equipment for this procedure. Carry out the isolation and draining procedure as follows:

� Open the electrode cover guard, taking care to avoid knocking the electrodes.

� Remove only one electrode at a time (avoids risk of incorrect reconnection)

� Remove the four nuts, washers and clamping plate, extract the electrode and the gasket carefully without damage to seat face.

� Inspect the vessel seat, removing any remnants of old gasket and taking care not to damage the seat.

� Apply a high temperature, copper / lead bearing grease to the studs to reduce contact friction between nuts, studs and washer, so avoiding excessive loading on the studs and possible shearing.

� Fit a new gasket to the electrode and carefully insert into the electrode port. Ensure that the gasket is located correctly, replace the clamping plate, washers and nuts, and tighten the nuts evenly using a torque wrench until the bottom face of the clamping plate meets the corresponding face of the pressure vessel. 70Nm (50lb ft) is usually sufficient. Max. Limit 110Nm (80lb ft)Replace the electrical lead(s) and guard. Re-commission as stated below.

2091445B

4006 & 4007 VOL D1 TAB-5-274

BHELVISION 20 M


3.7.1 Vessel commissioning

The method given allows the vessel to fill slowly with condensate from the steam leg through a crack Opened steam valve and for warming to continue at a controlled rate as the water is forced back through the crack opened water valve by the few inches of differential water pressure which exists when the steam valves are opened.

Notify the unit operator of the intention to commission the vessel, in accordance with recognised procedures.

� Check that the electrode guard is in place.

� Close drain & vent valves. � Open water and steam

isolating valves nearest to boiler drum.

� Crack opens the isolating steam valve nearest to the pressure vessel. Check with the unit operator that the vessel slowly fills with condensate (about 10 -15 minutes).

� Crack opens the isolating water valve nearest to the pressure vessel. Check with unit operator that the water level is falling to approximately normal water level.

� Open water valves fully.

2091445B

4006 & 4007 VOL D1 TAB-5-275

BHELVISION 20 M


3.8.1 BHELVISION Electrode Simulator

The BHELVISION Electrode Simulator (BES) can be connected to the EWLI BHELVISION – 20M equipment to simulate the working of sixteen electrodes mounted in a pressure vessel. Sixteen switches, one for each electrode, can be set individually to provide a simulated

WATER or STEAM condition at any electrode level. The switches are numbered 1 to 18, where 1 corresponds to the lowest level electrodes and 18 to the highest level electrode. A general view of the Electrode Simulator is shown in Fig. – 3.8.2

The Eighteen switch circuits can be considered as two groups, one group comprising the ODD channel circuits, and the other the EVEN channel circuits. Each group has its own earth connection, which is common to all switches in that group. The circuit diagram for the BHELVISION Electrode Simulator (BES) is shown in Fig. 3.8.1

Fig.3.8.1 CIRCUIT DIAGRAM OF BHELVISION ELECTRODE STIMULATOR

3.8 Accessories

2091445B

4006 & 4007 VOL D1 TAB-5-276

BHELVISION 20 M


Each switch circuit consists of a 2-position switch (STEAM / WATER) and two resistors (1Meg ohm and 68K ohm) connected so that the resistance between the common earth and the numbered wire connection for that switch will simulate a WATER or STEAM condition, depending upon the switch setting.

Connection for the BES is by means of a 3-metre long (approx). Cable with 25-pin ‘D’ connector (male) termination. In the Ascertor cabinet a set of connection from probe excitation signal at TB2 terminals 1 to 14 have been provided and terminated with 25 pin ‘D’ (female) connector.

Fig.3.8.2ELECTRODE SIMULATOR

3.8.2 OPERATION

The BES shall be electrically linked by connecting the 25 pin ‘D’ connectors (Male and Female at BES and Ascertor cabinet respectively) together. Pressure

vessel shall be isolated from process by closing water and steam isolation valves. Also empty the pressure vessel in full by opening the drain valves.

Now the EWLI - BHELVISION 20M system is ready for simulation.

Toggling the switches between Water and Steam position will simulate the condition of Water and Steam respectively, for individual electrodes numbered 1 to 12 from bottom to top.

By operating the 12 switches (1 to 12) the following shall be simulated and tested. The Table below shows the condition applicable for a Standard 12 port system (Vision range 550mm) With Alarm / Trip levels. For this project the following port shall be switched for Alarm / Trip levels.

High Trip

10th Port Water to Steam

175mm Above NWL

Low Trip

3rd Port Water to Steam

175mm Below NWL-

High Alarm


125mm Above NWL

Low Alarm


125mm Below NWL

2091445B

4006 & 4007 VOL D1 TAB-5-277

BHELVISION 20 M


BES SWITCH STATUS

EWLI - PORT INDICATION

ALARM/TRIP/ FAULT STATUS

ANALOG O/P in mA

1 to 12 - Steam 1 to 12 - Red Low Alarm - Yes V.Low Trip - Yes

4.00

1 - Water 2 to 12 - Steam

1 - Green 2 to 12 - Red

- do - 5.33

1 to 2 - Water 3 to 12 - Steam

1 to 2 - Green 3 to 12 - Red

- do - 6.67


1 to 3 - Green 4 to 12 - Red - do -

8.00



Low Alarm - Yes 9.33



Nil 10.67



Nil 12.00



Nil 13.33



Nil 14.67



High Alarm - Yes 16.00



High Alarm - Yes V. High Trip - Yes

18.67

1 to 11 - Water 12 - Steam

1 to 11 - Green 12 - Red

High Alarm - Yes V. High Trip - Yes

18.67

1 to 12 - Water 1 to 12 - Green High Alarm - Yes V.High Trip - Yes

20.00

Water above Steam/ Steam below Water

As per individual port condition

Trip - Disabled Alarm - Abled Fault - Yes

4.00

2091445B

4006 & 4007 VOL D1 TAB-5-278

BHELVISION 20 M


3.8.3Torque wrench

� Check that the ratchet direction is correct.

� Select the correct size of 1/4”, 3/8” or 1/2” socket and push it onto the square.

� Tighten the nut until the tool ‘clicks’ and is felt to ‘give’ slightly. STOP pulling immediately.

The tool will automatically re-set itself when hand pressure is relaxed, ready for the next tightening cycle

Fig.3.8.3 TORQUE WRENCH

3.8.3.1 USING THE TORQUE SPANNER

Torque Spanner is essential for the correct tightening of the high tensile bolts used in pressure vessel.

Both over and under-tightening can cause the failure of highly stressed bolt, so they must be correctly tightened to be safe.

The even tightening produced by a torque spanner used on clamping plate head studs prevents electrode damage or studs being broken.

3.8.4 OPERATING INSTRUCTIONS

Setting tools fitted with a Metal Adjusting Knob

a)Pull the adjusting knob out of the body tube until it clicks into position(about 6mm). It may be necessary to turn the knob silightly while pulling.

b)Rotate the adjusting knob untile the cursor line lies opposite the desired torque. c)Push the metal knob back to its ‘Free Wheel’ position to avoid accidental setting alteration.

2091445B

4006 & 4007 VOL D1 TAB-5-279

BHELVISION 20 M


Fig. 3.8.4 OPERATING INSTRUCTION .

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4006 & 4007 VOL D1 TAB-5-280

BHELVISION 20 M


3.8.5 ACCIDENT PREVENTION A torque wrench is a precision tool for the accurate tightening of nuts and bolts. It should never be used as a lever to undo frozen nuts. When tightening or loosening a nut it is possible that something might break or slip. Always stand firmly with one foot well in front of the other and pull the torque wrench towards you. Make sure that the socket is the correct size to fit the nut and in good condition. Use an extension driver between the wrench and the socket if there is any danger of scrapping your knuckles due to a sudden release. Accidents can occur using the simplest tools. So ,

“BE SAFETY CONSCIOUS.”

3.8.6 DO’S AND DON’TS Do set the spanner at a lower figure (3/4 of maximum) than required; tighten all nuts and re-set to final figure and tighten again. Do pull tool squarely from the center of the handle. Do refer to the maker’s handbook, or recognised repair manual for correct torque setting. Do see that bolt threads are clean and lightly oiled before torque tightening. Don’t adjust the tool either above the maximum on the scale or below the minimum. Don’t snatch the tool when tightening, a smooth continuous pull gives more accurate results. Don’t put oil through the hole in the body tube, or adjust the screw beneath it.

2091445B

4006 & 4007 VOL D1 TAB-5-281

BHELVISION 20 M


ACCESSORIES OF TORQUE WRENCH

2091445B

4006 & 4007 VOL D1 TAB-5-282

BHELVISION 20 M


3.8.7 Face cutter

The face cutter is used to repair damaged electrode port seats. Damage may occur either due to a leaking electrode gasket or due to the sealing gasket being incorrectly removed. If the leak is allowed to continue, the damage will become too severe for effective repair. Repair is possible by machining the seat to produce a clean sealing face. Positioning of the face cutter has shown in fig. 3.8.11 The following instructions enable the electrode port to be effectively repaired.

� Remove electrode and gasket as per the instruction briefed earlier.

� Whenever the electrode is changed (or) taken out for inspection, the gasket shall be replaced with a new one. The gasket can be removed with the help of gasket remover shown in fig. 3.8.7.

� Carefully examine the damaged seat and assess whether the damage is too severe to be remedied by site machining. This decision must be based on judgement, but as a guide, the minimum amount of metal should be removed from the seat to enable a clean seating face to be produced. The maximum that may be removed is 1.15mm.

NOTE:The stated maximum, 1.15mm, is the total amount of metal that can be removed from any one seat during the lifetime of the vessel. This is not the amount than can be

removed at each machining. If it is necessary to remove more metal from a seat than this stated maximum, guidance first be sought from BHEL - TRICHY. Using a depth gauge or depth micrometer, measure the depth of the electrode port and compare it with the dimension stated in Fig. 3.8.8NOTE: If the depth of the electrode port exceeds the dimension stated in Fig. 3.8.8 + 1.15mm, guidance must be sought from BHEL - TRICHY before proceeding with the machining operation. Inspect the face cutting tool Fig. 3.8.10 to ensure that the teeth of the cutter are in good order. Attempting to machine an electrode seat using a cutter with a damaged tooth may well result in worse damage to the electrode seat. At all times during this operation, great care must be taken that the minimum amount of material is allowed to fall through the electrode port into the body of Pressure Vessel. MACHINING

� Insert the cutter into the electrode port with the shaft protruding outwards, ensuring that it is seated properly.

� Fit the guide plate over the shaft of the cutter and locate it over the four studs in the body of the vessel.

� Fit the nuts and washers onto the studs and tighten finger tight.

� Attach a spanner or socket wrench (11 mm) size to the square section, drive end, of the cutter.

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3.8.7 Face cutter ( contd.,)

� Turn the cutting tool gently in a clockwise direction. As the cutter turns, a degree of “feel” is required to ensure that the cutter is making the correct depth of cut.

� If the four securing nuts are

not sufficiently tight, the cutting face of the tool will skim across the electrode seat and not remove any metal. The nuts should then be tightened gently until it is felt that the correct cut is being made. If the four securing nuts are over tight, the cutting teeth of the tool will bite too deeply into the electrode seat and the cutter will “bind up”. In this instance, the four securing nuts should be slackened until lit is felt that the correct cut is being made.

� At regular intervals, the nuts, washers, guide plate and cutter should be removed and the electrode seat examined to check progress of the repair operation.

� If the seat is still scored, reassemble the tool and continue the operation until, when examining the seat unmarked, bright metal shows.

� At this point, the operation is discontinued and the electrode port thoroughly cleaned out to remove

any swarf. Ensure that the swarf is removed outwardly and not into the vessel.

� The depth of the electrode port should now be measured and the difference between this and the measurement shown in Fig. 3.8.8 must be less than 1.15mm.

� The difference calculated as above has now to be machined off the face of the electrode clamp plate. The clamp plate must have a raised face machined on it as shown in Fig. 3.8.9

The vessel interior must be cleaned of any foreign material by using air or by washing through with water with the drain valves open until the vessel body is clear of metal debris.

3.8.8 MARKING AND RE-ASSEMBLY

The electrode clamping plate and the electrode port, which have just been machined, must both be stamped with a unique identification mark. This is due to the fact that this electrode clamp plate will only provide the required seal when used in this electrode port.

� Re-assemble the electrode into the pressure vessel, taking care to use a new Metaflex gasket.

� Re-commission the vessel.

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Fig. 3.8.7 GASKET REMOVEL TOOL

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Section 4 – Trouble shooting

4.0 General

Trouble shooting procedure is intended to help the user to identify the nature of problem from a set of defined elimination process. Also this procedure helps to eliminate minor problems such as loose contacts, blown fuse, blown LED etc., In case of PCB defects, it is not recommended to correct at site. Faulty PCBs may be sent to BHEL / Trichy for rectification.

Faults may be diagnosed from the following flow charts and from the block diagrams. Power supply must be switched off while replacing any module. Dangerous supply voltages are present in the relay driver module ‘D’ Connector. Precautions must be observed while handling RD2018.

If a module or power supply is found to be defective, it is preferable to replace it, with a new one and not to attempt local repair.

4.1 Required Tools � Card extender � Digital Multimeter � Continuity Tester � Screw driver � Electrode Simulator Keys � Ascertor cabinet key � Trip disable keys

4.2 Visual InspectionThe visual inspection checks that will aid in trouble shooting

Pressure vessel � Electrode damage � Protector Hood damage � Loose,Broken cables

Ascertor cabinet � Both PS2018 modules LED

‘ON’� Modules configuration as per

legend pasted on cabinet door � RD2018 LED status

4.3 Function check

1) Momentarily just press once gently and leave the test push button in display unit mounted in UCB. 2) For approx. 1 sec. all display LEDs show water (green) and all LEDs switch to steam and stay for approx. 1 sec. 3) During this period, trip relays will maintain the status prior to test function.4) After approximate duration of 2 secs. test period, equipment goes to normal mode.5) This facility is given only in UCB display unit. 6) This on line testing can be done whenever required to verify the healthiness of the equipment.

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4.4 Trouble shooting charts

Trouble shooting Flow Charts guide the maintenance engineer to eliminate cause of trouble in a systematic manner

4.4.1 Faulty Display

Do not attempt to work on Faulty electronic modules at site. Faulty PCBs may be sent to BHEL / Trichy for rectification.

4.4.2 Water above Steam

4.4.3 Steam below Water

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THE EWLI-BHELVISION VESSEL AND PROBE SYSTEM PROVIDES A SELF FLUSHING FEATURE THAT PREVENTS ACCUMULATION OF DEBRIS IN THE VESSEL. THIS ELIMINATES THE NEED FOR PERIODIC BLOWING DOWN OF THE VESSEL. DO NOT BLOW DOWN THE VESSEL IF A BLOCKAGE IS SUSPECTED.

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Section 5 – Installation/ part drawings

OGA for Ascertor cabinet - Drg. No. 3-97-088-14787

OGA for Display unit - Drg. No. 3-97-088-14788

OGA for operating floor indication box - Drg. No. 3-97-088-11993

Layout of ascertor cabinet - Drg. No. 3-97-088-15689

Internal wiring diagram - Drg. No. 3-97-088-15688

External connection diagram - Drg. No. 3-97-088-15687

Basic Scope and cabling Diagram - Drg. No. 3-97-088-14457

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Section 6 – Specifications 6.1 Pressure Vessel & accessories Material Forged carbon steel, thick wall design Operating pressure 207 Kg/Sq.cm Operating temp 450 Deg.C Steam / Water distance 635mm for 12 probes Probe sight range 550mm Steam / water connection 25mm bore, butt weld Electrode pitch 50 mm Material Thickness 115 mm

6.2 Displays Enclosure Polycarbonate/Aluminium Degree of Protection IP 55 LED HP make, highest bright, industrial grade, square type Size 99 (W) x 194 (H) mm Cutout 90 (W) x 184 (H) mm Depth 79 mm Special feature Display for fault status and remote test push button for

UCB display Mounting Suitable clamps for mounting provided.

6.3 Power supply Module PCB material & grade Glass epoxy FR4, 1.6mm thick 35 Micron copper thickness Mother board Suitable to fix behind 19 inch rack LED Indications Provided Power connection Thro’D-Connector cable of 0.5 Sq.mm silver coated copper Multistrand, PTFE insulated wire Power supply Linear power supply Input / Output 230V AC / 12V DC @ 3.0Amp Load regulation Better than + 0.2 % Line regulation + 0.1 % Over voltage protection (13.8 V DC) Short circuit protection 120 % rated curremt Mounting Suitable for 19 inch rack Indication Power on Ambient (max) 55 Deg C

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6.4 Electrode Type Flange type Body material SS Tip Titanium tip with ceramic insulator Gasket Spiral wound metaflex gasket

6.5 Special cable Application Interconnection between probe and ascertor cabinet Specification 10 pair, 0.6 Sq.mm PTFE insulated, nickel plated copper,

pair shielded and collective shielded, extruded.

6.6 Ascertor Cabinet Size 600 (W) x 600 (H) x 350 (D) mm Degree of Protection IP 55 Application Outdoor Operating Temp. 50 Deg.C Relative Humidity 95% Power supply 230V AC Outputs Alarm / Trip contacts & Analogue outputs Cabinet accessories Door lock, rain canopy, earth stud & mounting plate Mounting Wall mounted Mounting accessories Supplied

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Section 7 – Checklists 7.1 INSTRUCTION BEFORE INSTALLATION

1. Visual inspection to check damages, if any.

2. Check the items received are as per shipping list

3. Ensure availability of following drawings/documents :

a) Drum fittings b) Ascertor GA & Display GA c) Layout arrangement d) Interconnection detail e) Jumper details f) Scope and cabling diagram

4. Check for correct supply of UCB/Operating floor display.

5. Ensure the location of ascertor cabinet as much close as possible to pressure vessel.

7.2 CHECK LIST BEFORE COMMISSIONING

1. Entire installation shall be checked

thoroughly as per drawings. 2. Check complete interconnection as

per drawing. 3. Check all terminals for secured

connection. 4. Check the modules position as per

rack layout arrangement. 5. Check the jumper settings as per

requirement. 6. Check for correct display unit at

operating floor and UCB. 7. Check the input voltage. 8. Check IR by using 500 V Megger.

7.3 MONTHLY CHECK LIST FOR ASCERTOR

1. Check all cabling for secured connection

2. Check all modules are in its position 3. Check operation of relays 4. Check local & operating floor

displays. 7.4 VESSEL ISOLATION CHECKLIST After obtaining authority to isolate the vessel:

1. Close off the steam and water isolating valves nearest to pressure vessel.

2. Close off the steam and water isolating valves nearest to boiler drum.

3. Open drain & vent valves and proceed with work required.

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7.5 VESSEL COMMISSIONING CHECKLIST

1. Notify the unit operator of the

intention to commission the vessel, in accordance with recognised procedures.

2. Check that the electrode guard is in place.

3. Close drain & vent valves. 4. Open water and steam isolating

valves nearest to boiler drum. 5. Crack opens the isolating steam

valve nearest to the pressure vessel. Check with the unit operator that the vessel slowly fills with condensate (about 10 -15 minutes).

6. Crack opens the isolating water valve nearest to the pressure vessel. Check with unit operator that the water level is falling to approximately normal water level.

7. Open water valves fully

7.6 TORQUE WRENCH USAGE CHECKLIST 1. Check that the ratchet direction is

correct. 2. Select the correct size of 1/4”, 3/8” or

1/2” socket and push it onto the square.

3. Tighten the nut until the tool ‘clicks’ and is felt to ‘give’ slightly. STOP pulling immediately.

7.7 PLEASE ENSURE THE FOLLOWING BEFORE/DURING COMMISSIONING

1. The pressure vessel shall be mounted and supported as per DRUM FITTING drawing.

2. The pressure vessel guard assembly should not touch the electrode tip.

3. Check the cabling as per interconnection drawings

4. Check the modules position as per rack arrangement drawings. Do not change the module position.

5. Do not try to remove / replace the modules when the power is ON.

6. On line testing of equipment feature is provided from UCB mounted display unit only. Check correct installation of UCB display unit.

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TAB - 6

CUST: 4006 & 4007

PROJECT: BHATINDA R&MPREPARED : M.MURUGAPRABUCHECKED : K. RATHNASEKAR

APPROVED : S.RAMACHANDRAN

DATA SHEET FOR PNEUMATIC ACTUATORCONTROLS AND INSTRUMENTATION/PE(FB)

FILEREF: CI:BHAT :PCINDENT/00 DT: 18-Sep-10

TAGNO APPLICATION PGMA QTY DUTY TORQUEin kgm

LLin mm

ANGLE OFTRAVEL

COIL RECSIZE (Bore X Stroke)

SLNO

HFE10,20 AA101 PA A&B VANE REGN 97599 2 R 125 248 90 08"x16"1

HFE51-54 AA101 COLD AIR DAMPER 97599 4 R 7 160 90 04"x04"2

HFE61-64 AA101 HOT AIR DAMPER 97599 4 R 31 230 90 06"x08"3

HLB10,20 AA101 FD-A&B VANE REGN 97599 2 R 10 200 90 04"x08"4

HNA35 AA001 PRI. AH OUTLET 97599 1 R 151 310 90 10"x16"5

HNA37 AA001 SEC. AH OUTLET 97599 1 R 242 350 90 12"x16"6

HNC10,20 AA003 ID FAN INLET DAMPER 97599 2 R 175 248 90 10"x16"7

Saturday, September 18, 2010 Page 1 of 1

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TAB - 7

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bhel instrumentation

Documents

drum level instrumentation

sadc system list of

bhel tab

list of lt servomotors

schedule of dampers

schedule of servomotors

system measurement

soot blower control