The document outlines the startup procedures for a pulverized coal fired boiler, detailing the necessary conditions and permissives for various components like induced draft fans, forced draft fans, and mills. It includes checks for lubrication oil pressures, temperatures, vibrations, and other operational parameters to ensure safe and effective startup. Additionally, it describes interlocks, trip conditions, and protections related to boiler operation and safety management systems.

1. Pulverized Coal Fired
Boiler Startup Procedure
By
Ashvani Shukla
C&I
Reliance

2. Index
• Startup Procedure of Boiler and Auxiliaries
1. Induced Draft Fan
2. Forced Draft Fan
3. Primary Air Fan
4. Mills
5. Coal Feeders
6. Air Pre Heaters
7. Burners

3. ID Fan
• START PERMISSIVES
• ID FAN REGULATING DAMPER MIN POSITION (< 10%)
• ID FAN SCOOP MIN POSITION (< 10%)
• ID FAN OUTLET GATE - FULL CLOSED
• ID FAN INLET GATE - FULL CLOSED
• LUBE OIL PRESSURE ADEQUATE (> 0.8 KG/CM2) [TAG - HNC11CP201]
• ID FAN BEARING TEMP NOT HI (< 850 C)
• MOTOR BEARING TEMP NOT HI (< 950 C)
• MOTOR WINDING TEMP NOT HI (< 1050C, ALL 6)
• ANY FLUE GAS PATH (A OR B) AVAILABLE
• APH - A ELECTRIC OR AIR MOTOR ON
• APH - A FLUE GAS INLET DAMPER & OUT LET GATE OPEN PATH - A AVAILABLE
• ESP - A PASS OUT LET GATE OPEN
• OR
• APH - B ELECTRIC OR AIR MOTOR ON
• APH - B FLUE GAS INLET DAMPER & OUT LET GATE OPEN PATH - B AVAILABLE
• ESP - B PASS OUT LET GATE OPEN
• HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)
• 15 SEC TIMER SHOULD ELAPSE AFTER THE PREVIOUS START OF ANY HT MOTOR (BFP, ID,
CWP)

4. • INTERLOCKS
STAND BY LOP STARTS
• IF FAN IS RUNNING AND LUB OIL HEADER PRESURE < 0.6 KSC (60 SEC
TIME DELAY) OR
• IF FAN IS RUNNING AND RUNNING LOP TRIPS >1 SEC AND OTHER LOP IN
STANDBY.
ID FAN INLET AND OUTLET GATE WILL OPEN ON AUTO, IF
• ID FAN IS RUNNING (60SEC DELAY) [IF OTHER FAN IS NOT RUNNING GATE
WILL OPEN IMMEDIATELY] OR
• ID FAN A & B ARE NOT RUNNING.
ID FAN INLET /OUTLET GATE CLOSE PERMISSIVE WILL BE AVAILABLE ONLY
WHEN FAN NOT RUNNING.
ID FAN INLET/OUTLET GATE CLOSE ON AUTO IF ID FAN TRIPS AND OTHER ID
FAN IS RUNNING & ONE FD FAN IN SERVICE.
AFTER START COMMAND
• OUTLET & INLET GATE CLOSE, IGV & SCOOP GO FOR MINIMUM FOR
SELECTED FAN
• SELECTED FAN MOTOR STARTS
• OUTLET & INLET GATE CLOSE, IGV & SCOOP GO FOR MINIMUM FOR
STAND BY FAN IF IT IS NOT IN SERVICE
• OUTLET GATE OPENS & THEN INLET GATE OPENS FOR THE STARTED FAN.
RUNBACK ON ONE ID FAN TRIPPING IS 90MW.

5. PROTECTIONS
S.N. DESCRIPTION
VALUES TIMER
(SEC)ALARM TRIP
1. 1 ID FAN BRG TEMP (DE & NDE) 0C 60 75 85 5
1. 2
ID FAN MOTOR BRG TEMP (DE &
NDE) 0C
60 85 95 5
1. 3
ID FAN BRG VIBRATION
(MM/SEC)
0.5 4.5 -
-
1. 4
MOTOR BRG VIBRATION
(MM/SEC)
0.5 4.5 -
1. 4
LUBE OIL PRESSURE (KG/CM2)
[HNC11CP205]
1.0 0.4 0.2 10
1. 6
H/C COOLER OIL I/L TEMP (0C)
[HNC12CT201]
95 100 110 -
1. 7
H/C COOLER OIL O/L TEMP (0C)
[HNC12CT202]
70 80 90 -
1. 8
ID FAN MTR WDG TEMP (0C) [2 /
6]
80 105 120 5
1. 9
H/C LUBE OIL PRESSURE
(KG/CM2)
[HNC22/11CP201-4]
1.0 0.8 0.6
15
DURING
STARTIN
G
1. 10
H/C LUBE OIL FILTER DP
(KG/CM2)
< 0.4
0.65 - HIGH
0.7 - V HIGH
- -
1. 11
POST PURGE FAN TRIP FROM
BMS *
- 10 + 75
-175 /
+150
-

6. ID Fan
• ID & FD FANS WILL TRIP ON POST PURGE IF
FURNACE PRESSURE EXCEEDS > +150 OR < -175
MMWC AFTER PURGE COMPLETE AND BEFORE HFO
TRIP VALVE OPENS.
• POST PURGE TRIP: AFTER 5 MINUTES OF PURGING,
BOILER AIR FLOW > 40%, ALL FEEDERS & MILLS
OFF, ALL OIL VALVES CLOSED, NO FLAME
DETECTED, ALL GAS VALVES CLOSED, THEN BOTH
ID FANS AND FD FANS WILL TRIP IF FURNACE
PRESSURE VERY HIGH OR VERY LOW OCCURS
• CONSCUTIVE START TIMER WILL RESET TO ZERO
WHEN ALL 6 WINDING TEMPERATURE < 500C &
BREAKER STOP > 2 HOURS.

7. FD FAN
• START PERMISSIVES
• LUB OIL PRESSURE > 0.8 KSC
• CONTROL OIL PRESSURE > 8.0 KSC
• BLADE PITCH AT MINIMUM POSITION (<10%)
• OUT LET DAMPER CLOSED
• FAN BEARING TEMPERATURE NOT HIGH (<850C)
• MOTOR BEARING TEMPERATURE (DE/NDE) NOT HIGH (<850C)
• MOTOR WINDING TEMPERATURE (<1050C)
• ANY ID FAN IS RUNNING & OTHER FD FAN IS OFF
• (SECOND FD FAN WILL START ONLY IF BOTH ID FANS ARE
RUNNING)
• HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)

8. Sr.N. DESCRIPTION
VALUE
TIMER
(SEC)ALARM TRIP
1. 1
MOTOR WINDING TEMPERATURE
(0C) [2 / 6]
80 105 120 5
1. 2
FD FAN & MOTOR BRG TEMP (DE
& NDE) 0C
60 85 95 5
1. 3 FAN BRG VIBRATION (MM/SEC) 0.5 4.5 -
-
1. 4
MOTOR BRG VIBRATION
(MM/SEC)
0.5 4.5 -
1. 5 POST PURGE FAN TRIP FROM BMS - 10 + 75
-175
/
+150
-
1. 6 BOTH ID FANS OFF / TRIP FROM FSSS
PROTECTION

9. PA FAN
• PERMISSIVE
• PA FAN LUBE OIL PRESSURE ADEQUATE (> 0.8 KSC) [HFE11CP201]
• H/C SCOOP MIN. POSITION (< 5%)
• FAN INLET REGULATING DAMPER MIN. POSITION (< 5%)
• FAN OUTLET DAMPER FULL CLOSE
• MOTOR BEARING TEMP. (DE & NDE) NOT HIGH (< 85OC)
• FAN BEARING TEMP. (DE & NDE) NOT HIGH (< 75OC)
• ALL MOTOR WINDING TEMP. NOT HIGH (< 105OC)
• PURGE COMPLETED
• ANY FD FAN IS RUNNING.
• HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)
• WINDING TEMP NOT HIGH AND BOTH APH PATH ARE I/S
• APH-A ON
• APH-A PA I/L & O/L DAMPER FULL OPEN AND APH-B ON
• APH-B PA I/L & O/L DAMPER FULL OPEN
OR [ANY APH ON AND OTHER PA FAN NOT I/S]

10. INTERLOCKS
AFTER GIVING START COMMAND TO PA FAN
• FAN MOTOR STARTS.
• OUT LET DAMPER OF STARTED FAN OPENS AFTER 60 SECONDS (IF
DAMPER IN AUTO)
STAND BY LOP OF PA FAN STARTS
• IF FAN IS RUNNING AND LUB OIL PRESURE < 0.6 KSC (60 SEC TIME DELAY)
OR
• IF FAN IS RUNNING AND RUNNING LOP TRIPS.
SECOND SEAL AIR FAN WILL START AUTOMATICALLY
• IF ANY PA FAN IS RUNNING AND SEAL AIR TO COLD PA DP IS LOW (< 100
MMWC) FOR 10 SEC. AND SEAL AIR FAN NOT RED TAGGED AND OUT OF
SERVICE IS NOT ALARM NOT PERSISTING OR
• FIRST SEAL AIR FAN FAILED TO START AFTER A START COMMAND
SEAL AIR FAN (S) WILL STOP ON ANY OF FOLLOWING CONDITIONS
• BOTH PA FANS NOT RUNNING FOR 15 SEC.
• BOTH SEAL AIR FANS RUNNING AND SEAL AIR TO COLD PA DP NOT LOW
AND COMMAND GIVEN FOR STOPPING.

11. PROTECTION
Sr.N. DESCRIPTION
VALUES
TIMER
(SEC)ALARM TRIP
1. 1
LUB OIL PRESSURE (KSC)
[HFE11CP205]
>1.0 0.4 0.2 2 SEC
1. 2
MOTOR BEARING TEMP. (DE & NDE)
(OC)
50-60 85 95 5
1. 3 FAN BEARING TEMP. (DE & NDE) OC 40-50 65 75 5
1. 4 FAN BEARING VIBRATION (MM/SEC) 1.0 4.5 -
-
1. 5
MOTOR BEARING VIBRATION
(MM/SEC)
1.0 4.5 -
1. 6 MOTOR WINDING TEMP (OC) [2 / 6] 80 105 120 5 SEC
1. 7
H/C WORKING OIL COOLER I/L TEMP.
(OC) [HFE12CT201-3]
<95 100 110 2 SEC
1. 8
H/C WORKING OIL COOLER O/L TEMP
(OC) [HFE12CT202-3]
<70 80 90 2 SEC
1. 9
H/C LUB OIL PRESSURE (KSC)
[HFE12CP201-4]
>1.0 <0.8 0.6
15
DURING
STARTI
NG
1. 10 H/C LUBE OIL FILTER DP (KG/CM2) < 0.4
0.4 - HIGH
0.6 - V
HIGH
- -
1. 11 BOILER TRIP FROM FSSS - - TRIP -

12. BOWL MILL
• PERMISSIVES
BOTH PA FANS RUNNING OR ONE PA FAN RUNNING AND NO MILL IN SERVICE.
IGNITION ENERGY AVAILABLE
• AT LEAST 3 OIL GUNS IN SERVICE AT THE ADJACENT OIL ELEVATION OR
• ADJACENT COAL FEEDER SPEED > 50% & FEEDER RUN FOR 50 SEC AND BOILER LOAD > 30 %
• BOILER LOAD > 30% AND MORE THAN 2 X1 ELEVATION BURNERS IN SERVICE (ONLY FOR
MILL-A)
LUBE OIL OK
• LUBE OIL PRESSURE ADEQUATE (> 2.4 KSC) FOR 5 MIN CONTINUOUSLY
• OIL FILTER CLEAN (DP < 1.0 KSC)
• LUBE OIL LEVEL ADEQUATE
• SUMP OIL TEMPERATURE ADEQUATE (>22 0C)
PULVERIZER OUT LET TEMPERATURE < 940 C WITH GOOD QUALITY SIGNAL
MILL INERTING STEAM VALVE CLOSED AND BREAKER NOT IN TEST.
ALL MILL DISCHARGE VALVE & BURNER MANUAL ISOLATION VALVE OPEN (FORCED)
TRAMP IRON HOPPER VALVE OPEN (FORCED).
PULVERIZER BREAKER & GRAVIMETRIC FEEDER IN REMOTE.
COLD AIR GATE OPEN (FORCED).

13. FURNACE FIRING PERMISSIVE SATISFIED.
• SCANNER FAN AC OR DC RUNNING
• ALL BURNER TILT AT HORIZONTAL OR ANY OIL ELEVATION IN SERVICE
• PURGE COMPLETE
• BOTH MFT RELAY RESET
• NO FURNACE FIRING INHIBIT SIGNAL
• NO COAL/OIL/GAS/IGNITOR ELEVATION BURNERS TRIPPED PERSISTING.
HT MOTOR START PERMISSIVES SATISFIED (REFER HT MOTORS)
MILL TRIP RESET.
SLAVE QUALITY O.K
ACFS ELEVATION A / B / C NOT SELECTED
ACFS MDV / MMV / PAV / CIV STATUS O.K (FORCED)
PULVERIZER NOT RED TAGGED
SEAL AIR VALVE OPEN
PULVERIZER TO SEAL AIR DP > 200mmwc
MOTOR FEEDER NOT FAULTY
START PULV SEQUENCE COMMAND GIVEN

14. INTERLOCKS
• IF ANY PA FAN TRIPS TOP ELEVATION MILL WILL TRIP DIRECTLY
• LUB OIL PUMP WILL START ONLY IF SUMP LEVEL IS ADEQUATE &
OIL TEMPERATURE IS >15 0C
• HOT AIR DAMPER WILL OPEN BY 10% ON HOT AIR GATE OPENING.
• WHEN MILL IS STOPPED, COLD AIR DAMPER WILL GO FOR 5%
OUTTRACK OPEN & IF MILL SEAL AIR VALVE IS CLOSED COLD AIR
DAMPER WILL CLOSE COMPLETELY.
• MILL AIR FLOW DEPENDS ON FEEDER SPEED:
• FOR FEED RATE 0-33% AIR FLOW WILL BE 27.6 TPH & FOR FEED
RATE 33%-100% AIR FLOW WILL BE 27.6TPH TO 36 TPH LINEAR
• IF DUST IS IN SERVICE, 40% OF DUST FEEDRATE WILL BE ADDED
WITH FEEDER FEED RATE AND AIR FLOW WILL BE AS GIVEN ABOVE

15. SLNO DESCRIPTION
VALUES TIMER
(SEC)ALARM TRIP
1. 1 LUB OIL PRESSURE LOW > 2.4 1.2 0.75 10
1. 2 LUB OIL FILTER DP HIGH < 0.5 0.6 - 2
1. 3 LUB OIL TEMPERATURE HIGH (0C)
45
65 - 2
1. 4 LUB OIL TEMPERATURE LOW (0C) 20 - 2
1. 5 LUB OIL SUMP TEMPERATURE HIGH (0C) 40 - 52 2
1. 6 LUB OIL SUMP LEVEL LOW - - TRIP 10
1. 7 LUB OIL PUMP NOT RUNNING - - TRIP 2
1. 8 FEEDER I/S AND LOSS OF PA FLOW (T/HR) > 28 - 10 NO TD
1. 9
IGNITION ENERGY NOT AVAILABLE
(REFER INTERLOCK)
- - TRIP 5
1. 10 MFT ACTED - - TRIP -
1. 11 MILL DISCHARGE GATES CLOSE (BYPASSED) - - TRIP 2
1. 12 SEAL AIR TO MILL DP LOW (MMWC) 300 - 125 60
1. 13 LOSS OF PA FAN / PRESSURE TRIP
850 675
500 -
625 5
BOTH PA FANS STOPPED
AND ANY ONE MILL
RUNNING
TRIP -
1. 14
PA HEADER PRESSURE LOW TRIP
(PA HDR PR < 675 mmwc AND ALL MILL I/S)
MILL-C
TRIP
5 SEC
1. 15 BURNER MANUAL ISOLATION VALVE CLOSED (BYPASSED) - - TRIP -
1. 16
FD OR BFP TRIPPING RUNBACK:
ALL MILLS RUNNING AND (ONE FD FAN RUNNING OR
ATLEAST TWO BFP’s NOT RUNNING)
- - MILL-C
1. 17 EMERGENCY PB OPERATED TRIP
1. 18 LOSS OF PA FAN RUNBACK TRIP
IF 3 MILLS I/S
MILL-C -
MILL-B 2 SEC
IF MILLS-AB/AC/BC I/S TOP MILL -
1. 19
LOSS OF PULVERIZER TRIP
(FEEDER RUNNING AND PULV STOPPED/ RUNNING FB LOST)
TRIP 1 SEC

16. TOP MILL TRIPPING ON GEN BKR OPEN SIGNAL:
TOP MILL WILL TRIP IF (GEN ACTIVE POWER > 3
MW AND GEN BREAKER OPEN (10 SEC PULSE))
AND ANY OF THE FOLLOWING CONDITION EXISTS
• ANY TWO MILLS RUNNING AND 2 ELEVATIONS
IN SERVICE
• 3 MILLS IN SERVICE AND NO COREX IN SERVICE
• 3 MILLS IN SERVICE AND COREX X1 ELEVATION
IN SERVICE

17. LOS PANEL LOGICS
LUB OIL PUMP WILL START IF ALL THE FOLLOWING CONDITIONS ARE SATISFIED:
• LUB OIL LEVEL ADEQUATE (TD 10SEC)
• SUMP OIL TEMP ADEQUATE 15OC
• LOP START (LOCAL SWITCH OR LOP START PB FROM BMS)-BYPASSED
LUB OIL PUMP WILL STOP IF PULVERISER IS OFF FOR MORE THAN 5 MINUTES AND
NO CONTACT OF CRL34 EXISTS AND ANY OF THE FOLLOWING CONDITIONS ARE
SATISFIED:
• LUB OIL LEVEL VERY LOW (TD 10 SEC)
• SUMP OIL TEMP NOT ADEQUATE
• LOP ON AND LUB OIL PRESSURE VERY LOW (TD 10 SEC)
LUB OIL SYSTEM HEALTHY IF LOP IS ON AND ALL THE FOLLOWING CONDITIONS
EXISTS:
• LUB OIL PRESSURE NOT VERY LOW 1.2 KSC (TD 60 SEC)
• SUMP OIL TEMP ADEQUATE 15OC
• LUB OIL LEVEL ADEQUATE (TD 10 SEC)
• LUB OIL DISCHARGE FILTER CLEAR 0.6 KSC
LUB OIL SYSTEM FAILED IF ANY OF THE FOLLOWING CONDITIONS EXISTS:
• IF PULVERISER IS ON AND
• LOP NOT ON FOR 2 SEC OR SUMP OIL TEMP NOT ADEQUATE (TD 1 HOUR)
• LOSS OF A.C POWER AT PLOS PANEL FOR > 2 SEC
• LUB OIL LEVEL VERY LOW (TD 10 SEC)
• LOP ON AND LUB OIL PRESSURE VERY LOW (TD 10 SEC)

18. RAW COAL FEEDER
• PERMISSIVES
• MILL RUNNING (30 SEC TIME DELAY)
• FEEDER SPEED DEMAND AT MINIMUM AND FEEDER NOT RT
• FEEDER IN REMOTE
• COAL FIRING PERMISSIVE SATISFIED
• PA FLOW ABOVE MINIMUM >10 T/Hr
• BUNKER OUTLET GATE OPEN
• FEEDER INLET GATE OPEN
• FEEDER TRIP RESET
• MILL MOTOR NOT OVER LOADED
• MILL GROUP READY AND GROUP SEQUENCE STARTED
• IF MILL GROUP SEQUENCE IN AUTO AND FEEDER IN AUTO AND HOT AIR
GATE OPEN
• NO BOILER TRIP

19. PROTECTION
• LOSS OF COAL ON BELT (TIME DELAY 5 SEC.)
• SHEAR PIN FAIL
• MFT ACTED
• MILL MAIN MOTOR OFF
6.0 - AIR PRE HEATER
PERMISSIVE (ELE / AIR MOTOR)
• APH GUIDE BEARING TEMP NOT HIGH (<700C)
• APH SUPPORT BEARING TEMP NOT HIGH (<700C)
INTERLOCKS
• AIR MOTOR STARTS (SOLENOID VALVE DE-ENERGISES) WHEN ELE.
MOTOR TRIPS.
• AIR MOTOR STOPS (SOLENOID VALVE ENERGISES) WHEN ELECTRICAL
MOTOR STARTS.
• SUPPORT / GUIDE BRG LOP STARTS WHEN APH ELEC MOTOR / AIR MOTOR
ON AND APH GUIDE / SUPPORT BRG TEMP > 400C
• SUPPORT / GUIDE BRG LOP STOPS WHEN APH BRG TEMP < 400C
• STAND BY LOP WILL START WHEN AUTO START COMMAND IS PERSISTING
FOR MAIN LOP FOR 2 SEC. AND THE MAIN LOP IS NOT ON OR IF THE
RUNNING LOP TRIPS

20. AIR PRE-HEATER DAMPERS
FLUEGAS, SA & PA INLET/OUTLET DAMPER
• AUTO OPEN
• APH ELECTRIC / AIR MOTOR NOT ON AND
OTHER APH ELECTRIC / AIR MOTOR NOT ON
• AUTO CLOSE
• APH ELECTRIC / AIR MOTOR NOT ON AND
OTHER APH ELECTRIC / AIR MOTOR ON
• OPERATION OF INLET & OUTLET DAMPERS OF APH
(FOR AIR & FLUE GAS PATH)
• FAN SIDE DAMPER SHOULD BE OPEN, FOR OPENING
THE BOILER SIDE DAMPER
• BOILER SIDE DAMPER SHOULD BE CLOSED FOR
CLOSING FAN SIDE DAMPER

21. BURNER MANAGEMENT SYSTEM
PURGE PERMISSIVES
• ALL NOZZLE VALVES, IGNITOR VALVES CLOSED.
• LOTV, HOTV, COREX GAS TV & IGTV CLOSED.
• ALL SCANNER SENSE NO FLAME (ALL ELEVATION ¾ SCANNERS SHOWS NO
FLAME)
• BC 2/4SCANNER FLAME NOT ON
• AB 2/4SCANNER FLAME NOT ON
• AX1 2/4SCANNER FLAME NOT ON
• X1 2/4SCANNER FLAME NOT ON
• X3 2/4SCANNER FLAME NOT ON
• NO IGNITION FROM AX1 AND BC CORNERS
• NO DISCRIMINTING SCANNER FLAME ON
• ALL FEEDERS OFF
• BOTH PA FANS OFF
• MILLS A, B & C HOT AIR GATES CLOSED AND ACFS HOT AIR GATE CLOSED
• IGNITOR GAS & COREX GAS VENT VALVES OPEN
• ALL AUXLIARY DAMPERS MODULATING
• ELEVATION A, B, C AND XX OUT OF FOUR ELEVATION >/=TWO ELEVATIONS
SHOULD BE MODULATING

22. • CC, BC, AB, AX1, X1, X2, X3 OUT SEVEN ELEVATIONS >/= FIVE ELEVATIONS SHOULD BE
MODULATING
• OR
• ELEVATIONS A, B, C AND XX OUT OF FOUR ELEVATION >/=TWO ELEVATIONS CONTROL STATION
OUT PUT COMMAND SHOULD BE >8%
• CC, BC, AB, AX1, X1, X2, X3 OUT SEVEN ELEVATIONS >/= FIVE ELEVATIONS CONTROL STATION
OUT PUT COMMAND SHOULD BE >8%
UNIT AIR FLOW GREATER THAN 40%(190 TPH)
• NO BOILER TRIP
• DRUM LEVEL VERY LOW FOR MORE THAN 5 SECONDS
• DRUM LEVEL VERY HIGH FOR MORE THAN 10 SECONDS
• FURNACE PRESSURE VERY LOW (2/3 LOGIC)
• FURNACE PRESSURE VERY HIGH (2/3 LOGIC)
• TOTAL AIR FLOW LESS THAN 40%
• BOTH ID FANS OFF
• BOTH FD FANS OFF
• LOSS OF REHEATER PROTECTION
• UNIT FLAME FAILURE TRIP
• LOSS OF ALL FUEL TRIP
• LOSS OF 220V DC MFT POWER, FOR MORE THAN 2 SEC.
• CRITICAL I/O MODULE FAIL
• EMERGENCY TRIP SWITCH ACTIVATED
• SPARE MFT TRIP
• 11.ANY ID FAN AND FD FAN RUNNING
• 12.CRITICAL IN PUT /OUT PUT MODULES FOR OIL GAS AND COAL ARE IN GOOD QUALITY

23. FUEL OIL VALVES
• PERMISSIVES
• LOTV OPENS ONLY IF ALL THE FOLLOWING CONDITION PERSISTS
• NO MFT ACTIVE
• LFO SUPPLY PRESSURE ADEQUATE (HJF60CP101)>6 Ksc
• ELEVATION AX1 ALL LFO VALVES CLOSED
• LOTV TRIP CONDITIONS DOES NOT EXIST
• LFO TRIP VALVES NOT RED TAGGED
• LFO TRIP VALVE CLOSE FEED BACK EXIST
• LFO BOTH HEADER PT’S NOT IN BADQUALITY
• ATOMIZING AIR PT NOT IN BADQUALITY (HJN10CP101)
• MODULE STATUS OK
• HOTV OPENS ONLY IF ALL THE FOLLOWING CONDITION PERSISTS
• NO MFT ACTIVE
• HOTV CLOSED
• ATOMIZING STEAM HEADER PT NOT BADQULITY
• HFO HEADER PT’S NOT BAD QULITY
• SLAVE MADULE STATUS OK
• HO SUPPLY PRESSURE ADEQUATE >=8 Ksc (HJF40CP102)
• ALL HO NOZZLE VALVES CLOSED
• HO SUPPLY TEMPERATURE ADEQUATE >=100 DEG C (HJF30CT101)

24. • HO RETURN TRIP VALVE OPEN
• HO TRIP VALVE CLOSE COMMAND NOT EXISTS
• HOTV NOT RED TAGGED
HORV OPENS ONLY IF ALL FOLLOWING CONDITION PERSIST
HO RETURN TRIP VALVE OPEN PUSHBUTTON PRESSED
• ALL HO NOZZLE VALVES CLOSED
IGNITOR TRIP VALVE OPENS ONLY IF THE FALLOWING CONDITIONS PERSISTNO MFT
ACTIVE
• IGTV IN CLOSE CONDTION
• ALL IGNITOR VALVES OF AX1 AND BC CLOSED
• IGNITOR GAS SUPPLY PRESSURE ADEQUATE>=0.75 KSC (SFA20CP101)
• IGNITOR TRIP VALVE TRIP CONDITION NOT EXISTS
• IGTV NOT RED TAGGED AND CLOSED
• BOTH PRESSURE TRANSMITTERS ARE GOOD QUALITY
• SLAVE MODULE GOOD QUALITY
IGNITOR FIRING PERMISSIVE
• AL TRIP CLEAR AND 1 MINUTE TIMED OUT
• MFT RELAY RESET
• IGTV OPEN
• IGNITOR SUPPLY PRESSURE >MIN
• IGNITOR SUPPLY PRESSURE <MAX
• EITHER IGNITOR FAN RUNNING OR IGNITOR TO FURNACE DP NORMAL (>MIN
80MMWC)

25. • PROTECTIONS
HOTV CLOSES IF ANY OF THE FOLLOWING CONDITION PERSISTS.
• TEMPERATURE OF HFO IS VERY LOW (HJF40CT102)<=90 0C AND ALL HONV’S NOT CLOSED AND HO RTV
NOT OPENED
• PRESSURE OF HFO IS VERY LOW (2.5 KSC)(HJF40CP102/3/4) AND ALL HONV NOT CLOSED INITIAL TIME
DELAY 32 SEC NORMAL TIME DELAY IS 2 SEC
• ANY HONV NOT CLOSED ON NO FLAME DETECTED AFTER IGNITION PROVEN (TIME DELAY IS 20SEC) AND
ANY BURNER VALVE FAIL TO CLOSE
• ATOMISING STEAM PRESSURE VERY LOW (3.0 KSC (HJF60CP101/2/3) & 5 SEC TIME DELAY) AND
ALLHONV NOT CLOSED AND NO HO ELEVATION IN START/STOP>90 SEC AND HORTV NOT OPEN,
• MFT ACTS AND HFO RETURN TRIP VALVE NOT OPEN
• VALVE FAILED TO OPEN WITH IN 10 SEC
• VALVE FAILED TO CLOSE WITH IN 10 SEC
• NO FAULT IN HOTV FACE PLATE
• VALVE LIMIT SWITCH MISS MATCH
• HO PRESSURE BAD QUALITY
• ATOMIZING STEAM PT BAD QUALITY
• LOSS OF UNIT LOGIC POWER SUPPLY
LOTV CLOSES IF ANY OF THE FOLLOWING CONDITION PERSISTS
• LFO HEADER PRESSURE LOW (2.0 KSC) AFTER OPENING OF LOTV 32 SEC TIME DELAY
• ATOMISING AIR PRESSURE VERY LOW TRIP (2.5 KSC & 5 SEC TIME DELAY), PROVIDED ANY OF LONV IS
OPEN AND ATOMIZING AIR PRESSURE LOW AND NO LFO ELEVATION IN START /STOP FOR >70 SEC
• VALVE FAILED TO CLOSE WITH IN 10 SEC AFTER GIVING CLOSE COMMAND (LOTV TRIPPED)
• VALVE FAILED TO OPEN WITH IN 10 SEC AFTER GIVING OPEN COMMAND (LOTV TRIPPED)
• NO FAULT LOTV FACE PLATE

26. • ANY LONV NOT CLOSED ON NO FLAME DETECTED AFTER IGNITION PROVEN
(TIME DELAY IS 20SEC AND ANY BURNER VALVE FAIL TO CLOSE)
• BOTH LFO HEADER PT’S BADQUALITY
• BOTH ATOMINZING AIR PT BAD QUALITY
• IGNITOR BURNER VALVE FAILED TO CLOSE MORE THAN 20 SEC AFTER FLAME
FAILURE
• LOSS OF UNIT LOGIC POWER SUPPLY
• MFT ACTIVE
IGNITOR TRIP VALVE LOGIC
IGNITOR TRIP VALVE CLOSES IF ANY OF THE FOLLOWING CONDITION EXISTS
• BOILER TRIP (MFT)
• IGNITOR GAS PRESSURE VERY LOW (0.2 KSC)(SFA20CP102) / HIGH (40 KSC)
(SFA20CP101) PROVIDED ANY OF IGNITOR BURNER VALVES NOT CLOSED FOR
MORE THAN 2 SEC.
• IGNITOR BURNER VALVE AX1/BC FAILED TO CLOSE MORE THAN 20 SEC. AFTER
SENSING NO FLAME AND ANY BURNER VALVE FAIL TO CLOSE
• VALVE FAILED TO OPEN WITH IN 10 SEC
• VALVE FAILED TO CLOSE WITH IN 10 SEC
• IGNITOR GAS PRESSURE TRANSMITTER BAD QUALITY
• LOSS OF UNIT LOGIC POWER SUPPLY
NO TIME DELAY IS THERE FOR IGNITOR HEADER VENT VALVE CLOSING AFTER TRIP
VALVE OPENING
FOR ALL OIL BURNERS, WHILE SCAVENGING IGNITOR VALVE OPEN TIME IS 45 SEC

27. OIL BURNER SEQUENCE.
ON START COMMAND FOR ANY PAIR
• IGNITOR CORNER VALVE OPENS PROVIDED IGNITOR NO FLAME PERSIST AND
IGNITOR FIRING PERMISSIVE SATISFIED AND START COMMAND GIVEN.
• PAIR START WILL INITIATE ELECTRIC SPARK FOR 10 SEC WITH IN 10 SEC IGNITOR
HAS TO BE PROVEN (IONIC FLAME MONITOR DETECTS THE FLAME AND IGNITOR
FLOW IS ADEQUATE)
• IF IGNITOR PROVEN, ATOMISING AIR / STEAM VALVE OPENS (2-3 SEC). THEN OIL
VALVE OPENS (2-3 SEC).
• IF SCANNER SENSES FLAME BEFORE 70 SEC, GUN STABLISES.
• IGNITOR STAYS FOR 70 SEC FROM INSTANT OF START COMMAND.
• IGNITOR CORNER VAVLE STOP/CLOSE WILL BE INITIATED AFTER CORNER OIL
NOZZLE VALVE OPEN (BURNER START TRIAL COMPLETION) WITH 15 SEC TIME
DELAY
• IGNITOR IS ALSO BROUGHT DURING SCAVENGING OR THE ASSOCIATED
ELEVATION BURNERS HAVE PLANNED SHUT DOWN OR STOP COMMAND
ATOMIZING AIR/STEAM VALVE OPEN
• LFO/HFO SELECTED
• ASSOCIATED CORNER IGNITOR TRIAL TIME COMPLETED
• OIL GUN ENGAGE
• SCAVENGING VALVE SHOULD BE CLOSED CONDITION
• START MEMORY PERSISTING

28. BURNER IN SERVICE WILL COME
• LFO/HFO SELECTED
• OIL START MEMORY.
• ONCE OIL VALVE FULL OPENS AND 15 SEC ELAPSED AND WITH IN THIS
PERIOD OIL FLAME DETECTED FROM MAIN FLAME SCANNE
UNIT FLAME FAILURE
• THE PROTECTION GETS ARMED WHEN ANY OF THE FOLLOWING
CONDITION PERSISTS FOR > 2 SEC.
• ANY COAL FEEDER PROVEN
• AX1 OR BC OIL ELEVATION ¾ NOZZLE VALVES OPEN WITH HFO & HFO
PRESSURE > 4 KSC
• COREX X1 (2/4) / X2 (3/4) / X3 (3/4) GAS BURNERS IN SERVICE AND
COREX GAS PRESSURE > 30% (100 MMWC)
• WHEN ALL THE ELEVATIONS VOTED TOGETHER FOR NO FLAME FAILURE
TRIP OCCURS
ELEVATION VOTING
• ELEVATION C VOTES WHEN ANY OF THE FOLLOWING CONDITION
PERSISTS
• FEEDER C NOT PROVEN FOR > 2SEC OR SIGNAL BADQUALITY. AND BC
ELEVATION (3/4 NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE OR
SIGNAL BADQUALITY
• BC ELEVATION 2/4 SCANNER SHOWS NO FLAME AND BC ELEVATION (3/4
NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQULITY.

29. ELEVATION B VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS
• FEEDER B NOT PROVEN FOR > 2 SEC OR SIGNAL BADQULITY. AND BC ELEVATION
(¾ NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQULITY
• AB ELEVATION 2/4 SCANNER SHOWS NO FLAME AND ELEVATION BC 2/4
SCANNER SHOWS NO FLAME AND BC ELEVATION (¾ NOZZLE VALVE NOT OPEN)
OIL NOT IN SERVICE OR SIGNAL BADQUALITY
ELEVATION A VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS
• FEEDER A NOT PROVEN FOR >2 SEC OR SIGNAL BADQULITY. AND AX1 ELEVATION
(¾ NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE AND AX1 HFO SELECTED.
• AB ELEVATION 2/4 SCANNER SHOWS NO FLAME AND ELEVATION AX1 2/4
SCANNERS SENSE NO FLAME AND AX1 ELEVATION (¾ NOZZLE VALVE NOT OPEN)
OIL NOT IN SERVICE.
ELEVATION X1 VOTES WHEN ANY OF THE FOLLOWING CONDITION PERSISTS
• ELEVATION X1 NOT IN SERVICE 2/4 AND AX1 ELEVATION (¾ NOZZLE VALVE NOT
OPEN) OIL NOT IN SERVICE OR SIGNAL BADQUALITY.
• ELEVATION AX1 2/4 SCANNER SHOWS NO FLAME AND AX1 ELEVATION (¾
NOZZLE VALVE NOT OPEN) OIL NOT IN SERVICE OR SIGNAL BADQUALITY AND X1
2/4 SCANNER SHOWS NO FLAME.
ELEVATION X2 VOTE WHEN ANY OF THE FOLLOWING CONDITION PERSISTS
• X2 ELEVATION NOT IN SERVICE OR X1 ELEVATION 2/4 SCANNER SHOWS NO
FLAME AND ELEVATION X3 2/4 SCANNER SHOWS NO FLAME.
ELEVATION X3 VOTE WHEN ANY OF THE FOLLOWING CONDITION PERSISTS
• WHEN X3 2/4 SCANNER SHOWS NO FLAME OR X3 ELEVATION NOT IN SERVICE.
•

30. LOSS OF ALL FUEL.
• THE PROTECTION GETS ARMED WHEN ANY IGNITOR AT ANY ELEVATION GETS PROVEN.
• BOILER WILL TRIP ON LOSS OF ALL FUEL WHEN ALL THE FOLLOWING CONDITION PERSISTS
• ALL COREX NOZZELS VALVE CLOSED/TRIPPED
• AX1 AND BC ELEVATION ALL HONV CLOSED/TRIPPED
• ALL FEEDERS OFF/TRIPPED
• AX1 ELEVATION ALL LONV CLOSED/TRIPPED
• ALL IGNITOR VALVE CLOSED/TRIPPED OR IGTV NOT OPEN/TRIPPED
REHEATER PROTECTION
THIS PROTECTION GETS ARMED, WHEN ANY OF THE FOLLOWING CONDITION EXISTS
• ANY FEEDER PROVEN.
• ANY COREX BURNER PROVEN
• AX1>/=3/4 WITH HFO
• AX1 4/4 WITH LFO +BC>/=1/4
• BC >/= 3/4 WITH HFO
• AX1= 2 WITH LFO +BC=/>1
• AX1=/>1 WITH LFO+BC=/>2
• AX1=/>1 WITH HFO+BC=/>2
BOILER WILL TRIP ON THIS PROTECTION WHEN ANY OF THE FOLLOWING CONDITION PERSISTS FOR 10 SEC.
• GCB OPENS AND HPBP CV < 2% OPEN.
• BOTH LPBP CVS < 2% OPEN.
• BOTH LPBP STOP VALVES CLOSED.
• BOTH MAIN STEAM VALVES (BOILER) ARE CLOSED.

31. LESS THAN FIRE BALL & LOSS OF A.C. (NOT INCLUDED AT PRESENT)
• BOILER WILL TRIP ON THIS PROTECTION WHEN ALL THE FOLLOWING
CONDITION PERSISTS
• ANY ELEVATION (AX1, BC, A, B, C, X1, X2, X3) STARTED & LOSS OF AC
POWER FOR 2 SEC
• ALL FEEDERS OFF
• AX1 OR BC ELEVATION NOT IN SERVICE {ELEVATION IN SERVICE
MEANS ¾ HFO NOZZLE VALVES OPEN AND HFO PRESSURE > 30%}
IGNITOR AIR FAN
• START PERMISSIVE
• FAN NOT OUT OF SERVICE
• FAN NOT RED TAGGED
• IGNITOR TO FURNACE <75 MMWC
• OTHER FAN FAIL TO START
• OTHER FAN FAIL TO STOP
•
• STOP PERMISSIVE
• IGNITOR TO FURNACE DP >75 MMWC AND OPERATOR STOP
COMMAND
• EMERGENCY STOP FROM LOCAL

32. SCANNER AIR FAN
• START PERMISSIVE
• FAN NOT OUT OF SERVICE
• SCANNER TO FURNACE DP<150MMWC
• OTHER FAN FAIL TO START
•
• STOP PERMISSIVE
• STOP FROM DCS AND F SCANNER TO FURNACE DP>150 MMWC
• SCANNER FAN DISCHARGE PR LOW 230MMWC AND SCANNER TO
FURNACE DP LOW 220MMWC
• SCANNER AIR FAN EMERGENCY DAMPER
• OPEN PERMISSIVE
• BOTH FD FANS OFF
• CLOSE PERMISSIVE
• ANY FD FAN RUNNING
•

33. ADDITIONAL COAL FIRING SYSTEM
(ACFS)
ACFS PAV’S PERMISSIVES.
• ALL MDV’S CLOSED.
• ALL BIV’S OPENED.
• ADJACENT IGNITION ENERGY PROVEN.
• ELEVATION SELECTED FOR ACFS.
• FURNACE FIRING PERMISSIVE SATISFIED.
• FD FAN RELEASE.
• UNSELECTED ELEVATION PAV’S NOT OPEN.
• ACFS COLD AIR GATE OPEN.
ACFS HOT AIR GATE PERMISSIVES:
• ANY ONE-ELEVATION PAV’S FULL OPEN.
• HOT AIR GATE CLOSED.
• HOT AIR GATE NOT RED TAGGED.
ACFS CIV’S PERMISSIVES:
• ALL PAV’S OPENED.

34. • UNSELECTED ELEVATION CIV’S FULL CLOSED.
• ACFS PA FLOW ADEQUATE.
• ACFS PA HEADER TEMP NOT HIGH.
ACFS COMPRESSOR PERMISSIVES:
•
• DIV-1 OPEN TO GROUP A/C.
• CONVEYING GROUP TRIP RESET.
• COMPRESSOR TROUBLE RESET.
• DIV-A & B OPEN TO SELECTED ELEVATION.
• ALL CIV’S OF SELECTED ELEVATION OPEN.
• ANY ONE ELEVATION SELECTED FOR ACFS.
• MFT RELAYS RESET.
•
ACFS PS PUMP PERMISSIVES:
•
• COMPRESSOR RUNNING.
• COMPRESSOR DISCHARGE PRESSURE ADEQUATE.
• CONVEYING GROUP TRIP RESET.
• PS PUMP DISCHARGE PRESSURE NOT VERY HIGH.
•
ACFS RAL PERMISSIVES:
•
• PS PUMP RUNNING.
• COMPRESSOR DISCHARGE PRESSURE ADEQUATE.
• PS PUMP DISCHARGE PRESSURE NOT VERY HIGH.
• CONVEYING GROUP TRIP RESET.
•

35. ACFS BAG HOUSE FAN PERMISSIVES:
ON STARTING OF ANY PS PUMP, BAG HOUSE BLOWER WILL START IN
AUTO AND CORRESPONDING KGV WILL OPEN AFTER 15 SEC OF
BLOWER RUNNING.
BAG HOUSE BLOWER WILL STOP IN AUTO AFTER BOTH RAL STOPPING
AND KGVS WILL CLOSE AFTER BLOWER STOP.
ACFS CONVEYING GROUP EMERGENCY TRIPS:
• LOSS OF COMPRESSOR TRIP.
• LOSS OF ACFS PA FLOW TRIP.
• ACFS SELECTED ELEVATION MDV OPEN TRIP.
• ACFS SELECTED ELEVATION MMV OPEN TRIP [BYPASSED]
• ACFS LOSS OF IGNITION ENERGY TRIP.
• ACFS SELECTED ELEVATION DIV CLOSE TRIP.
• ACFS LOSS OF PA FAN / PRESSURE TRIP.
• BOILER TRIP – ACFS.
• ACFS SLAVE BAD QUALITY TRIP.

36. SECONDARY AIR DAMPER CONTROL
• WIND BOX DP (MMWC) CONTROL SET POINT
WILL BE GENERATED AS PER REQIREMENT
DAMPER OPERATION:
XX ELEVATION:
• MODULATE TO MAITAIN WIND BOX TO
FURNACE DP AS PER ABOVE CURVE (TABLE)
• CLOSE WHEN BOILER LOAD >30%AND X3 NO
BURNERS IN SERVICE
• OPEN FULL WHEN WB TO FURNACE DP GOES
>THAN 240MMWC AND RESET AT 175MMWC
• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD
OFF OR BOTH ID OFF)

37. AB ELEVATION:
• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• CLOSE WHEN BOILER LOAD >30%AND MILL-A/ACFS PAV’S NOT OPEN FOR MILL-A AND
MILL-B/ACFS PAV’S NOT OPEN NOT OPEN FOR MILL-B
• OPEN FULL WHEN WB TO FURNACE DP GOES >THAN 175MMWC AND RESET AT
125MMWC
• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)
CC ELEVATION:
• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• CLOSE WHEN BOILER LOAD >30%AND MILL- C NOT IN SERVICE /ACFS PAV’S NOT OPEN
FOR MILL-C
• OPEN FULL WHEN WB TO FURNACE DP GOES >THAN 175MMWC AND RESET AT
125MMWC
• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)
X1 ELEVATION:
• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• CLOSE WHEN BOILER LOAD >30% AND AX1, X1 AND X2 NO BURNERS IN SERVICE
• OPENING PROPORTINAL TO COREX C-HEADER PRESSURE (180MMWC TO 600MMWC
SADC WILL OPERATE 30% TO 100%)WHEN X1 IN SERVICE
• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)
X2 ELEVATION:
• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• CLOSE WHEN BOILER LOAD >30% AND AX1, X1AND X3 NO BURNERS IN SERVICE
• OPENING PROPORTINAL TO COREX C-HEADER PRESSURE (180MMWC TO 600MMWC
SADC WILL OPERATE 30% TO 100%)WHEN X2 IN SERVICE
• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)

38. X3 ELEVATION:
• MODULATE TO MAITAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• CLOSE WHEN BOILER LOAD >30% AND X2 AND X3 NO BURNERS IN SERVICE
• OPENING PROPORTINAL TO COREX C-HEADER PRESSURE (180MMWC TO 600MMWC SADC WILL
OPERATE 30% TO 100%)WHEN X3 IN SERVICE
• OPEN FULL ON MFT (BOILER TRIP OR BOTH FD OFF OR BOTH ID OFF)
•
A ELEVATION:
• MODULATE TO MAINTAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• OPENING PRAPORTIONAL TO ELEVATION FEED RATE FROM 20 TO 70%
• CLOSE WHEN THE BOILER LOAD >30% AND AX1 AND A NOT IN SERVICE
• OPENS FULL ON MFT
•
B ELEVATION:
• MODULATE TO MAINTAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• OPENING PRAPORTIONAL TO ELEVATION FEED RATE FROM 20 TO 70%
• CLOSE WHEN THE BOILER LOAD >30% AND BC OR B NOT IN SERVICE
• OPENS FULL ON MFT
•
C ELEVATION:
• MODULATE TO MAINTAIN WIND BOX TO FURNACE DP AS PER ABOVE CURVE (TABLE)
• OPENING PRAPORTIONAL TO ELEVATION FEED RATE FROM 20 TO 70%
• CLOSE WHEN THE BOILER LOAD >30% AND BC OR C NOT IN SERVICE
• OPENS FULL ON MFT
•
• AFTER 40 SEC OF MFT ALL THE DAMPERS TO AUTOMATICALLY MODULATE TO MAINTAIN 40
MMWC WIND BOX PRESSURE

39. Thank you