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APPROVED
CHECKED
N51-99K-N116
Revised according to owner comment after software FAT in KM. (28 Jan. 2005) KS
1 Y. Ono Y.Ono
DRAWING NO.
RP0
12 (DNV)
() 12
CONFERRED
SCALE ORDER
K1A32/38/44
61500 G377
N51-99K-N116
Kongsberg Functional Design Document (KFDD) Boiler Control System DSME 2227/2228/2235
7069
This document describes the scope and functions of the Kongsberg Maritime Vessel Control System SVC delivered to the specified vessel. Functions within other systems are not described in this document. This document when as built will serve also as operator documentation together with KM standard SVC Operator Manual 1001854
Revision: Document version: Number of pages: Reason for issue For internal comments For Approval Reissue for approval Reissue for approval Made by BA OHJ SN OHJ Checked HAE HAE MS GM
Document number: Customer doc number: Contract number: Rev. A B C D E Date 28.04.2004 13.05.2004 15.07.2004 26.01.2005
0D 0.4 93
Approved HAE HAE EW OSL
Kongsberg Maritime AS
Kongsberg Maritime AS
History
Revision Description of Change
A B C
For internal comments For Approval Re-issue for approval, insert comments from MHI, dated 10 July 2004 K.Saito / MHI Marine Boiler Re-issue for approval, insert comments after FAT, January 05
References
Doc No Description
1001854 / 0D / Page 2 of 93
Kongsberg Maritime AS
Table of contents
1 GENERAL ITEMS ..................................................................................................5 1.1 Definitions/Abbreviations .....................................................................................5 1.2 Flowchart symbols.................................................................................................8 2 RESPONSIBILITIES ..............................................................................................9
3 BOILER GENERAL ...............................................................................................9 3.1 General ..................................................................................................................9 3.2 Burner Management ............................................................................................13 3.3 CPU Redundancy ................................................................................................13 3.4 Power Distribution...............................................................................................14 4 BURNER SEQUENCES........................................................................................15 4.1 Fuel Oil Burning..................................................................................................16 4.2 Gas burning .........................................................................................................24 4.3 Burner Auto Mode...............................................................................................29 4.4 Burner Automatic Increase/Decrease ..................................................................30 4.5 Fuel Mode Changeover .......................................................................................34 4.6 Fuel Oil Boost UP ...............................................................................................42 4.7 Nitrogen Purge of Gas Supply Lines...................................................................43 4.7.1 N2 Purging of Main Line to Vent............................................................... 44 4.7.2 N2 Purge of Gas Header to Vent ................................................................ 45 4.7.3 N2 Purge of Gas Burner to Furnace ........................................................... 46 4.7.4 N2 Purge of Gas Header & Burner to Furnace........................................... 46 4.7.5 Main Line Vent Valves .............................................................................. 48 5 BOILER CONTROL.............................................................................................49 5.1 Drum Water Level Control..................................................................................49 5.2 Main Steam Temperature Control .......................................................................51 5.3 Atomizing Steam Pressure Control .....................................................................52 5.4 Steam Purge Pressure Control .............................................................................53 5.5 FO Pump Discharge Pressure Control.................................................................54 5.6 Steam Pressure Control .......................................................................................55 5.7 Steam Dump Control ...........................................................................................62 5.8 Flame Eyes ..........................................................................................................65 5.9 FDF STBY Fan....................................................................................................66
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Hot Start Valve ....................................................................................................67 Viscometer Outlet Valve .....................................................................................68 Fuel/Atomizing Valve Abnormal ........................................................................69 Output to Main Turbine.......................................................................................70 BOILER TRIP .......................................................................................................71
7 BOILER OPERATION PANELS ........................................................................78 7.1 BGB Graphic Panel .............................................................................................78 7.2 Manual Loader Functions....................................................................................82 7.3 Emergency Operation..........................................................................................84 7.3.1 No.1 or No.2 part........................................................................................ 84 7.3.2 Common Part.............................................................................................. 85 8 SOOT BLOWING SEQUENCES ........................................................................85 8.1 Long Soot Blower Sequence ...............................................................................87 8.2 Rotary Soot Blower Sequence.............................................................................87 8.3 Boiler & Economizer Soot Blower Sequence .....................................................88 8.4 Economizer Soot Blower Sequence ....................................................................90 9 ATTACHMENTS ..................................................................................................93
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1 GENERAL ITEMS
1.1 Definitions/Abbreviations
Local control Remote control Manual control Automatic control Operation of the equipment is outside the IAS system (Switchboard or local panels). Operation of the equipment is performed from the IAS system. Operation of the equipment is performed manually by the operator from the IAS operator stations or BGB. Operation of the equipment is performed by IAS control logic (remote mode only).
ABC AVR BGB BNP CCR CTR DG DP E/R ECR EOP EOT ESD F&G FDF FDS FO FS
Automatic Boiler Control Automatic Voltage Regulation Boiler Gauge Board Burner Operation Panel Cargo Control Room Custody Transfer System Diesel generator Differential Pressure Engine room Engine Control Room Emergency Operator Panel Engine Order Telegraph Emergency Shutdown Fire and Gas Forced Draft Fan Functional Design Specification Fuel oil Field Station (Cabinet with controller and/or RIO modules)
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FV FW GMS HD HS HT HV I/O IAS IGC code IGV KM LD LNG LO LR LT LV MCC MCR MHI MLP MV MT NDU OS PMS PV RCS RCU
Forcing Vaporizer Fresh water Gas Management System High Duty Compressor Hand Switch High Temperature High voltage (6.6 kV systems) Input / output Integrated Automation System International Code for the Construction and Equipment of Ships carrying Liquefied Gases in Bulk. Inlet Guide Vane Kongsberg Maritime Low Duty Compressor Liquefied Natural Gas Lubrication oil Lloyds Register Low temperature Low Voltage (440V / 220 V systems) Motor Control Center Maximum Continuous Rate Mitsubishi Heavy Industries Manual Loader Panel Main Vaporizer Main Turbine Net Distribution Unit Operator Station Power Management System Process Variable Remote Control System Remote Controller Unit
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Remote Input Output Unit Soot Blower Relay Panel Set Point Simrad Vessel Control Sea water Turbine Generator Video Display Unit
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Description
This symbol represents any kind of processing function.
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2 RESPONSIBILITIES
Kongsberg Maritime is responsible for this document.
3 BOILER GENERAL
3.1 General
Two main boilers are installed, both with the following specifications: Maker: Type: Steam pressure: Steam temperature: Evaporation: Feed water temperature at ECO outlet: Efficiency Fuel Oil: Boiler design pressure: Auxiliary de super heater outlet: Steam quantity: Temperature: Max: 40,000 kg/h Max: 350 C , normal: 288.5 C. Mitsubishi Heavy Industries. MB-4E-NS2. 60.3 bar. 515 C. Normal: 50,000 kg/h , max: 61,500 kg/h 139,8 C. 88,5 % 76,5 bar
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RCU
RCU
RCU
RCU
HUB
HUB
HUB
HUB
HUB
HUB
RIO
RIO
RIO
Common AI/AO
RIO
RIO
RIO
Common DI/DO
RIO
Flame scanner #2
RIO
Flame scanner #2
RIO
Common DI/DO
RIO
RIO
RIO
RIO
Manual Loader
RIO
Manual Loader
RIO
Manual Loader
RIO
RIO
RIO
Div control
RIO
RIO
RIO
RIO
RIO
Operator Panel
RIO
RIO
RIO
SBP
RIO No2 Burner Control RIO No2 Burner Control
RIO
RIO
BGB
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BGB, Boiler Gauge Board The local board including graphic operator panel, manual loader functions, emergency operator function, some instruments. panels including BNP, MLP & EOP. BGB is MHI supply. Graphic Operation Panel This panel is located at the BGB. It contains lamps and switches for local boiler control also manual loader functions are included. Graphic Operator panel is MHI supply.
EOP, Emergency Operation Panel This panel is located locally at the BGB. From this panel FO burners can be started/stopped in case of emergency. EOP is MHI supply.
Soot Blower Relay Panel This cabinet is delivered by MHI. The cabinet controls soot blowing sequences of the two boilers. ABC RIO units are installed here for soot blower control. ABC Cabinets ABC cabinets consists of three cabinets . FS-11, Main boiler no1 control FS-13, Main boiler no2 control FS-12, Boiler common & soot blower control
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Boiler main functions: Start / stop of oil burners Start / stop of gas burners Nitrogen purge of gas lines Fuel mode changeover Burner automatic increase/decrease according to boiler load Automatic FO backup Automatic FO boost up in case of gas supply failure Drum water level control Steam temperature control Atomizing steam pressure control Purge steam pressure control FO pump pressure control Steam pressure control, including: - Boiler master control with load ratio control - Air flow control including O2 control - FO flow control - GAS flow control Steam dump control Local panels with operation. Boiler safety. Emergency operation.
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RIO Units
SBRP
RIO Units
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4 BURNER SEQUENCES
General. Starting / stopping of burners are made by a sequencer system within the IAS. This is applicable for either IAS control or BGB local control. A selector switch at the BGB decides which control place to be active. In case of any trouble during sequence execution a sequence jam status is issued. In case of sequence jam the running sequence will perform a clean up (error treatment). All sequences except stop sequences will be blocked until operator resets the sequence jam (reset button at IAS monitor, acknowledge button at BGB). Burner Start. FO / GAS start buttons are prepared separately which means operator freely can decide each burner firing mode. Burner asynchronous firing is allowed in manual mode. Burner Stop. FO / GAS stop buttons are prepared separately. NOTE: 1 burner firing at gas only is not recommended for safety reasons. Burner Auto mode. In order to select auto mode the burners must be firing in synchronous mode. Burner manual sequences is then inhibited. The following sequences are then available: Burner automatic increase, starts automatically. Burner automatic decrease, starts automatically. Mode change FO => Dual, need operator intervention to start. Mode change Dual => GAS, need operator intervention to start. Mode change GAS => Dual, need operator intervention to start. Mode change Dual => FO, need operator intervention to start. FO auto backup (GAS => Dual), starts automatically FO boost up (GAS => FO), starts automatically.
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Operator Preparations: Reset of all FO trip conditions. Reset of all boiler trip conditions. Start of FO supply pump. Start of FDF Open FO shutoff valve.
Sequence Description: At the time all interlocks are lifted the start FO sequence can be started. The starting will be carried out by a sequence controller according to following description. First the corresponding burner atomizing steam valve is opened. Furnace purge will then be carried out by opening of all burner air slide dampers and FDF vane is set to purge position. Furnace purge will be continued for 90 seconds (confirmed by air volume). When the furnace purge is completed the not starting burner air registers will closed and FDF vane will be set to start position. Fuel oil control valve will be set to start position. The igniter will be inserted and the spark activated. When igniter spark and position is confirmed the burner FO valve will be opened. Furnace purge sequence uses air flow signal from differential press transmitter (247B) for detection of sufficient air volume. Differential press transmitter for air flow detects press between wind box and furnace. And air flow is calculated based on measured press.
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Error
Force Fd Fan Vane To Start Pos. (5%) Timeout : 10 sec Close Bnr Register which are not set for start Timeout : 10 sec
Error
- Boiler FO Shutoff Valve Opened - All Bnr Fo Valves Closed - Not Fo Trip - All Burner Register Closed & - Not F/E Abnormal - All Bnr GAS Shutoff Valves Closed - If ignitor is bypassed then portable ignitor must be inserted(Limit Switch) - Not boiler trip - Stop Seq Not active - FDF Run - Not Seq Jam
Error - Boiler FO Shutoff Vlv Close Cmd - Boiler Trip - FO Trip Error OR
Error
- Air Rate Normal (8000-4000kg/h) & - FO Press Ok(>10bar) & - FO Temp Ok or Temp byps On OR Waiting timer 10s
Error
Error
- FO Valve opened & - Igniter inserted - Igniter In Down Position & Spark On & Portable Igniter Not Selected OR - Igniter In Down Position & Portable Igniter Selected & Spark On Waiting Timer: 2s - Burner Fo Valve 1 Opened & - Burner Fo Valve 2 Opened & - Flame Detected Direct Error if: - Falme Fail Waiting Timer: 5s
Open FO Valve 223B & Insert Igniter Timeout : 20 sec Activate Retractable Igniter if Not Portable igniter Selected Or Activate Portable Igniter if Selected Timeout : 10 sec
Error
Open Burner Fo Valve 225B Timeout : 10 sec Error (Flame fail is activated 7s afterFO vlv open cmd)
- Deactivate & Retract Igniter - Close Burner Register If Gas Burner Is Not Active - Close Atomize Steam Valves
Error
- Fd Fan Vane Released & - FO Control Valve Released Note: FO Valve 223B is Slow Acting Downstream side FO Valve 225B is Fast Acting
Error
End
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SEQ-2 Furnace Purging Condition for next step - Burner 1 Register Opened & - Burner 2 Register Opened & - Burner 3 Register Opened Action Open All Burner Registers Timeout : 15 sec
- Start from Burner Start seq. or - Manual Purge from BGB in Local mode or - Manual Purge from IAS in IAS mode
- FDF in Furn Prg Pos +/- 3% & - Air Flow > 40.000 Kg/h
Error
Error
Purge Status > 1min Or FDF Not RunOr Any FO Vlv Open Command Or FO Shut Valve Open & Any Bnr On
Set Reset
Furnace Purge Seq Failed - Release FD Fan Vane - Close All Burner Registers
End
Manual Purge. At the BGB there is a switch for purge request. This switch will activate the above mentioned sequence if boiler is stopped.
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Starting fuel oil burners, when another burner is on: In manual mode operator is responsible for checking FO pressure and boiler master demand by him self. Auto mode is described in the chapter for burner automatic increase / decrease. The individual fuel oil burners can be started and stopped either from the operator station (IAS control) or from the BGB (local control). Start FO burner 1 (by activating the start FO 1 pushbutton). Start FO burner 2 (by activating the start FO 2 pushbutton). Start FO burner 3 (by activating the start FO 3 pushbutton).
Sequence Description: The sequence starts by open the burner atomizing steam valve and closing of steam purge valve. Then igniter is lowered and simultaneously burner FO valves (up stream 225B & down stream 223B) are opened. The burner flame should be detected within 7 seconds after FO valves are opened if not burner will trip.
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Flowchart for starting fuel oil burners, when another FO burner is on:
Note : Only One Burner Can Be Started At The Time Condition for next step - Atm Steam Vlv Opened & - Steam Purge Vlv Closed & Action Open Atm Steam Vlv & Close Steam Purge Vlv Timeout : 10 sec Error SEQ-3 Start Oil Burner (Next FO Burner) Start Start Permissive Terminate - Burner On from BGB(local) if any flame on - Burner On from Monitor(IAS) if any fl on OR - Start Request from Bnr auto inc (SEQ-9 step 2 , SEQ-9 step 5)
Error
- Any Burner Is Active - Burner FO Valves Closed & - Burner Register Closed if Gas Burner is Off - Not Seq Jam - FO Press > 10 bar if Auto Mode
Error - FO Shutoff Vlv Close Cmd - Burner Fo Piston Valve Shutdown - Boiler Trip - FO Trip OR Note : If all burner flame on signals are llost before before a flame is detected on the burner being ignited the start sequence will be terminated.
Error
- Igniter In Down Position & Spark On & Portable Igniter Not Selected OR - Igniter In Down Position & Portable Igniter Selected & Spark On Or - Corresponding Gas Bnr On
Insert and activate Retractable Igniterif Not Portable igniter Selected Or Activate Portable Igniter if Selected If Corresponding GAS Bnr is Off Timeout : 30 sec
Error
Open Bnr FO Vlv (223B) & Open Bnr FO Vlv (225B) Timeout : 10 sec (Flame fail is activated 7s afterFO vlv open cmd)
Error
Error
Close Burner Register If Gas Burner Is Not Active Error Close Atomize Steam Valve Open Steam Purge Valve
End
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Stopping fuel oil burners: The individual fuel oil burners can be stopped either from the operator station (IAS control) or from BGB (local control). Stop FO burner 1 (by activating the stop FO 1 pushbutton). Stop FO burner 2 (by activating the stop FO 2 pushbutton). Stop FO burner 3 (by activating the stop FO 3 pushbutton). The stop of burners is always available and will terminate any start attempt. The following commands are executed: Closing individual fuel oil piston valves. De-energizing igniter (if energized). Retracting Igniter (if inserted). Closing burner register if gas burner is not active (individual gas valve closed). Steam purging of burner, atomizing steam valve will close (if no other burner is active). In case of stopping last burner a furnace purge will be carried out.
1001854 / 0D / Page 22 of 93
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No
- Burner 1 Register Opened & - Burner 2 Register Opened & - Burner 3 Register Opened
Error
- FDF in Purge psition (>80%) & - Air Flow > 40.000 Kg/h
Error
Timer 30 seconds
- FDF Released
Error
- Burner 1 Register Closed & - Burner 2 Register Closed & - Burner 3 Register Closed
Error
A Open Stm Purge Vlv & Open FO Recirc V if Last FO Bnr Timeout : 30 Sec
Error
FO Burner Extinguish Seq Failed - Close Burner FO Valves - Deactivate & Retract Igniter - Close Air Register if Gas Burner is Not Active
Timer 5 sec
Error
- Close Atomize Steam Valve - Open Steam Purge Valve if Any Burner On
Timer 30 sec - Release FDF Vane -Bnr Atm Stm Vlv Closed Close Bnr Atm Stm Vlv Timeout : 20 sec - Open FO Re-circ Valve if All FO Burners are Off
Error
End
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Manual Mode The individual fuel gas burners can be started and stopped from the IAS operator station or from BGB in local control. Start GAS burner 1 (by activating the GAS 1 ON pushbutton). Start GAS burner 2 (by activating the GAS 2 ON pushbutton). Start GAS burner 3 (by activating the GAS 3 ON pushbutton). Stop GAS burner 1 (by activating the GAS 1 OFF pushbutton). Stop GAS burner 2 (by activating the GAS 2 OFF pushbutton). Stop GAS burner 3 (by activating the GAS 3 OFF pushbutton)
Auto Mode: The operator may select FO/Dual/ GAS mode from the IAS operator stations. The transfer between modes is then made by a sequence program. Number of burners is decided by boiler load.
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Sequence Description: Gas burners can be started once the corresponding FO burner is in operation. In addition the master gas valve and boiler GAS valve must be opened, the burner GAS valves must be closed. The vent valves are controlled automatically by the sequences or by GAS valves positions. During GAS burner ON/OFF operations the N2 purging of lines/burners will be performed automatically when needed. At the end of gas firing the operator must manually close boiler GAS valve and master GAS valve. Flowchart for starting fuel gas burners:
Note : Only One Burner Can Be Started At The Time Condition for next step - Gas Ctrl Valve In Start Position Or - Any Other Gas Burner Is Active
SEQ-5 Start Gas Burner Action Check Gas Ctrl Vlv To Start Pos. If No Other Gas Burner Is Active Timeout : 10 sec
- Gas Burner On from BGB (Local Mode) - Gas Burner On from Monitor(IAS) OR - Start Req from Bnr auto inc/dec seq. (SEQ-9 step3, SEQ-9 step6)
Error
- Burner Gas Valve 1 Opened & - Burner Gas Valve 2 Opened &
Error
Master Gas Valve Open Boiler Gas shutoff valve Opened Burner Gas Valve1 Closed Burner Gas Valve2 Closed Not Boiler Trip Not FO Trip Not Gas Trip Master N2 Purge Sequence Not Active Header N2 Purge Sequence Not Active Header N2 Purge Valve Closed Burner N2 Purge Valve Closed Not Seq Jam Corresponding FO Bnr On
&
- Master Gas Valve Closed - Gas Trip Note : If Corresponding Oil Burner "Flame On" Signal Is Lost Before Gas Flame Is Detected, The Start Sequence Will Be Terminated. OR
End
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SEQ-6 Stop Gas Burner Condition for next step - Burner Gas Valve 1 Closed & - Burner Gas Valve 2 Closed Action Close Burner Gas Valves Timeout : 10 sec
Error
Error
Error
Error
Gas Burner Extinguish Seq Failed - Bnr register Closed Or - FO Bnr On Or - Furn Purge in Progerss Close Bnr Register If FO Bnr is Off & Not Furn Purge Timeout : 10 sec Error - Close Burner Gas Valves - Close Air Register if FO Burner is Not Active - Close Burner N2 Purge Valve
End
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Timer 5 sec
&
Error
Boiler Gas Valve Open Seq Failed - Close Boiler Gas Valve - Open Header Vent Valve - Release Gas Control Vlv End
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Error
No
FO Burning On ?
Yes - Hrd/Bnr N2 Purge to Furn Seq Run If FO Burning: Start Hrd/Bnr N2 Purge to Furn (SEQ-19) Timeout : 10 sec A Error
Yes - Hdr N2 Purge to Vent Run Start Hdr N2 Purge to Vent (SEQ-17) Timeout : 10 sec
Error
Boiler Gas Valve Close Seq Failed - Close Boiler Gas Valve - Close Hdr N2 Purge Valve - Open Header Vent Valve - Close All Burner Gas Valves - Release FDF A End
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&
OR
Bnr1 GAS Bnr2 GAS Burning Bnr3 GAS Burning Burning Dual Mode Bnr1 FO Burning Bnr1 GAS Burning
&
OR
& &
OR
& &
OR OR
GAS Mode Bnr1 GAS Bnr2 GAS Burning Bnr3 GAS Burning Burning
&
OR
&
Bnr1 FO Burning Bnr2 FO Burning Bnr3 FO Burning FO Trip Ctr Pos IAS FO Shut V Open Bnr1 Flame Fail Bnr2 Flame Fail Bnr3 Flame Fail
&
OR
OR &
Bnr1 FO or Gas Burning Bnr1 Gas Burning Bnr2 Gas Burning Bnr3 Gas Burning
OR
&
&
FO Trip
1001854 / 0D / Page 29 of 93
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Mode
Limit Boiler demand > 13,5 Gcal/h & FO pressure > 13 bar Boiler demand > 27,0 Gcal/h & FO pressure > 12 bar Boiler demand > 14,0 Gcal/h & total fuel calorie > 14,0 Gcal/h & FO press > 12 bar Boiler demand > 28,5 Gcal/h & total fuel calorie > 28,5 Gcal/h & FO press > 10 bar Boiler demand > 25,0 Gcal/h & GAS Press > 0,1 bar
Result 1 => 2 bnr 2 => 3 bnr 1 => 2 bnr 2 => 3 bnr GAS=>Dual
FO
Dual
2 bnr 2 bnr
GAS
Note: In case of burner increase in GAS mode, the GAS => Dual sequence will be activated. Then dual burner will increase if required. 12,4 Gcal/hr is equivalent to 1200kg/hr of fuel oil, 20,6 Gcal/h is equivalent to 2000 kg/h.
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Burner Decrease: Request for stopping burner will be calculated as follows: Mode No Of Bnr 3 bnr FO 2 bnr 3 bnr Dual 2 bnr 3 bnr GAS 2 bnr Limit Boiler demand < 16,0 Gcal/h & FO pressure < 5,5 bar Boiler demand < 8,0 Gcal/h & FO pressure < 5,0 bar & M/T stop for 15 min. Boiler demand < 16,0 Gcal/h & total fuel calorie < 18,0 Gcal/h Boiler demand < 9,0 Gcal/h & total fuel calorie < 10,2 Gcal/h & M/T stop for 15 min. Boiler demand < 17 Gcal/h & GAS hdr pressure < 0,12 bar Boiler demand < 6,0 Gcal/h & GAS hdr pressure < 0,1 bar Result 3 => 2 bnr 2 => 1 bnr 3 => 2 bnr 2 => 1 bnr 3 => 2 bnr GAS=>Dual
Main Turbine Interaction: In case of main turbine trip the numbers of burners are limited to maximum 2 burner.
TimerOff
30s
Crash Astern, Crash Stop (Burner No3 Auto Decrease) (By SEQ-10)
TimerOff
30s
& OR MT Telegraph Stop MT Telegraph Astern MT Vlv Lift > 50% &
Crash Ahead, Crash Stop (Burner No3 Auto Decrease) (By SEQ-10)
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- FO Mode: Boiler Demand & FO Prs - Dual Mode: Boiler Demand & Tot Calorie Input - GAS Mode: Boiler Demand & GAS Press - No of burners are 1 or more - Not MT Interlock by Crash Astern/Ahead/MT Trip - Auto mode selected - Bnr decrease Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - GAS => Dual Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Seq Jam - Not Burner Abnormal
OR
&
Error
Start GAS Burner 2 if: Dual Mode & GAS Bnr2 is OFF (SEQ-4) Timeout : 60sec
Error 3
Start FO Burner 3 (SEQ-3) if FO or Dual Mode GAS>Dual seq (SEQ-13) if GAS mode 5 Timeout : 60sec Start GAS Burner 3 if: Dual Mode & GAS Bnr3 is OFF (SEQ-4) Timeout : 60sec
Error
Error 6
End
*1) Ready:
FO Mode; FO Burner Start Permissive OK Dual Mode; FO Burner & Gas Burner Start Permissive OK
1001854 / 0D / Page 32 of 93
Kongsberg Maritime AS
&
Stop FO Burner 3 if: FO or Dual Mode (By SEQ-4) & Stop GAS Burner 3 if: Dual or GAS mode (By SEQ-6) Timeout : 60sec
Error
Stop FO Burner 2 if: FO or Dual Mode (By SEQ-4) & Stop GAS Burner 2 if: Dual mode (By SEQ-6) & GAS=>Dual (SEQ-13) if GAS mode Timeout : 60sec
Error
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Available sequence for change-over is: Fuel oil => <= Dual fuel => <= Fuel Gas. Special Mode: Low Load Gas Mode Low Load Gas mode can be selected either in dual mode condition or in gas mode condition. This mode enables gas only firing during main turbine in maneuvering zone.
FO => Dual Fuel: If activated the system will start up gas burners where oil burner is already on.
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Action Set GAS Control valve to start position Timeout : 1sec 1 No All Bnr's GAS vlv's closed Master GAS valve open Boiler GAS vlv open Burner mode = Auto Bnr Increase Seq Off Bnr Decrease Seq Off Dual => GAS Seq Off GAS => Dual Seq Off Dual => FO Seq Off FO Boost Up Seq Off Not Burner Abnormal Not Seq Jam
&
Error 2
- (Bnr1 GAS Bnr is ON & - (Bnr2 GAS Bnr is ON or Bnr2 FO Bnr is OFF) & - (Bnr3 GAS Bnr is ON or Bnr3 FO Bnr is OFF) Wating Timer 20 sec
Open Bnr1 GAS Valves (1&2) Open Bnr2 GAS Valves (1&2) if FO Bnr On Error Open Bnr3 GAS Valves (1&2) if FO Bnr On Timeout : 60sec 3 -Boiler Trip - FO Trip - GAS Trip
OR
- Stop GAS Burner 1 (SEQ-6) - Stop GAS Burner 2 (SEQ-6) - Stop GAS Burner 3 (SEQ-6) - Reset Add Air to Air Flow Controller - Reset GAS Control Vlv Start Position 6 End
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Dual => GAS: When mode switch is changed from dual to GAS, the system will stop oil firing.
SEQ-12 Mode: Dual => GAS Start Start Permissive Terminate - IAS mode: OR GAS button from Monitor is pressed.
Error
- Stop FO Bnr1 (SEQ-4) - Stop FO Bnr2 (SEQ-4) - Stop FO Bnr3 (SEQ-4) if Dual Bnr ON Timeout: 60sec
Error
- Master GAS valve open - Number of Dual bnr's are 2 or more - Boiler GAS vlv open - Bnr mode = Auto - Bnr Increase Seq Off - Bnr Decrease Seq Off & - FO => Dual Seq Off - GAS => Dual Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Bnr Abnormal - Not Seq Jam - GAS Press > 0.1 bar - LD Comp 1 or 2 Running - Not FO Auto Backup Order Active - Boiler trip - FO Trip - GAS Trip - Auto Backup Order - FO Boost Up Order OR
End
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GAS => Dual Fuel: When mode switch is changed from GAS to dual, the system will start up oil burners where gas burners are firing. Some process conditions will start GAS => dual sequence automatically by means of FO auto backup order. In case of LD compressor stop no3 burner will stop automatically FO Auto Backup.
Cargo Tk Press L Manouvering Zone Low Gas Mode Both LD Comp Stop Only Base Gas Bnr Firing No3 Bnr Stop & Gas Mode & OR FO Auto Backup Order
1001854 / 0D / Page 37 of 93
Kongsberg Maritime AS
Error
- Bnr1 Atm Stm vlv Opened or Bnr1 is OFF - Open Bnr2 Atm Steam Vlv & & - Close Bnr2 Stm Purg Vlv - Bnr2 Atm Stm vlv Opened or if GAS Bnr2 is ON Bnr2 is OFF & - Open Bnr3 Atm Steam Vlv & - Bnr3 Atm Stm vlv Opened or - Close Bnr3 Stm Purg Vlv Bnr3 is OFF if GAS Bnr3 is ON Timeout : 10sec
- Open Bnr1 Atm Steam Vlv & - Close Bnr1 Stm Purg Vlv if GAS Bnr1 is ON
Error
- GAS Mode - Boiler FO Vlv Opened - FO Burners no interlock active. - Burner mode = Auto - Number of GAS bnrs are 2 or more - Bnr Increase Seq Off & - Bnr Decrease Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Bnr Abnormal - Not Seq Jam - GAS PRESS > 0.1 bar
OR
- Bnr1 Stm Purge vlv Clsed or Bnr1 is OFF & - Bnr2 Stm Purge vlv Clsed or Bnr2 is OFF & - Bnr3 Stm Purge vlv Clsed or Bnr3 is OFF
Error
Error
- Bnr1 Dual Burning or Bnr1 is OFF & - Bnr2 Dual Burning or Bnr2 is OFF & - Bnr3 Dual Burning or Bnr3 is OFF & Waiting Timer 10sec
- Open Bnr1 FO Vlv 1&2 if GAS Bnr1 is ON - Open Bnr2 FO Vlv 1&2 if GAS Bnr2 is ON - Open Bnr3 FO Vlv 1&2 if GAS Bnr3 is ON Timeout : 10sec GAS => Dual Seq Failed Reset FO Control Valve to Start Position -Reset Air Bias -Reset FO Ctr V Start Pos
Error
End
1001854 / 0D / Page 38 of 93
Kongsberg Maritime AS
Dual => FO: When mode switch is changed from dual to FO, the system will stop gas firing. Flowchart for Changeover Dual => FO:
SEQ-14 Mode: Dual =>FO Start Start Permissive Terminate - IAS mode: FO button from Monitor is pressed. OR
Action Set Gas Extinguish Request to Gas Flow Controller Timeout : 180sec
Error
Stop GAS Bnr1 - GAS Burner 1 is OFF & Stop GAS Bnr2 - GAS Burner 2 is OFF & Stop GAS Bnr3 - GAS Burner 3 is OFF Timeout : 30sec Error
- Any FO burner On - Burner mode = Auto - Bnr Increase Seq Off - Bnr Decrease Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - FG => Dual Seq Off - FO Boost Up Seq Off - Not Bnr Abnormal - Not Seq Jam
&
OR
Dual => FO Seq Failed - Reset Gas Extinguish Request to Gas Flow Controller
End
1001854 / 0D / Page 39 of 93
Kongsberg Maritime AS
Low Load Gas Mode: Low Load Gas mode can be selected either in dual mode condition or in gas mode condition. This mode enables gas only firing during main turbine in maneuvering zone. Dual => Low Load Gas Mode: When LL gas mode is activated at dual mode, the boiler master will increase the calorie demand in order to increase gas pressure to over 0.1bar. When gas pressure is over the limit for changing to gas mode, then dual=>gas sequence is activated. After change to gas mode is complete boiler master low limit will be set depending on number of burners. Gas => Low Load Gas Mode: When LL gas mode is activated at gas mode, boiler master low limit will be set depending on number of burners. Note: Since Low Load Gas Mode sets a minimum boiler master demand main steam pressure might increase. In case main steam pressure is increased the dump control valve will open and keep the pressure at dump set point. Low Load Gas Mode Available: BMS Auto & 2 or 3 Bnr Firing & Dual or Gas Mode
1001854 / 0D / Page 40 of 93
Kongsberg Maritime AS
Low Load Gas Mode Exit: FO Mode Pushbutton Depressed, or Dual Mode Pushbutton Depressed or Gas Mode Pushbutton Depressed or Steam Press Over 62.9bar or Dump control valve over 70% or Gas mode dropout (Fuel mode is changed from gas to other mode due to FO boost-up or back-up.)
Boiler Master Low Limit: During changeover at dual 2 bnr: 17 Gcal/h During changeover at dual 3 bnr: 26 Gcal/h At low load gas mode and gas only firing: 13 Gcal/h
1001854 / 0D / Page 41 of 93
Kongsberg Maritime AS
Condition for next step - If Bnr1 GAS firing: Bnr1 Atm Stm V Opened Bnr1 FO Vlv 1&2 Opened Bnr1 Prg Stm V Closed & - If Bnr2 GAS firing: Bnr2 Atm Stm V Opened Bnr2 FO Vlv 1&2 Opened Bnr2 Prg Stm V Closed & - If Bnr3 GAS firing: Bnr3 Atm Stm V Opened Bnr3 FO Vlv 1&2 Opened Bnr3 Prg Stm V Closed & - FO Recirc V Opened
Action Open: Bnr1 Atm Stm V if Bnr firing Bnr2 Atm Stm V if Bnr firing Bnr3 Atm Stm V if Bnr firing Bnr1 FoVlv1&2 if Bnr firing Bnr2 FoVlv1&2 if Bnr firing Bnr3 FoVlv1&2 if Bnr firing Close: Bnr1 Prg Stm V if not firing Bnr2 Prg Stm V if not firing Bnr3 Prg Stm V if not firing FO Recirc Vlv Force FO Control Vlv to "FO Boost Up Order" Position Timeout: 6 sec
- Burners Firing in GAS mode - All Bnr FO Valves Closed - FO Shutoff Vlv Opened - Boiler in Auto Mode
&
-FO Trip Error Close Bnr1 FO Vlv's & Air register if No Flame or Purge steam vlv not closed or Atomize steam vlv not open Close Bnr2 FO Vlv's & Air Register if No IR Flame or Purge steam vlv not closed or Atomize steam vlv not open Close Bnr3 FO Vlv's & Air Register if No IR Flame or Purge steam vlv not closed or Atomize steam vlv not open Error
Wait 15 Sec
Close: - All Bnr GAS Vlv's - Boiler GAS Valve Timeout: 10 sec
End
1001854 / 0D / Page 42 of 93
Kongsberg Maritime AS
Vent Mast
Master gas valve
Gas Supply
GAS main line N2 purge valve
Vent
Vent
N2 Supply
GAS Control Valve Boiler GAS Valve Bnr 3 N2 Purge Valve
FWD (2)
CNTR (1)
CNTR (1)
AFT (3)
AFT (3)
1001854 / 0D / Page 43 of 93
Kongsberg Maritime AS
Error
Wait 90 Seconds
Error
Master N2 Purge Seq Failed - Master Vent Valve 1 Open - Master Vent Valve 2 Open - Master N2 Purge Valve Close
End
1001854 / 0D / Page 44 of 93
Kongsberg Maritime AS
Flowchart:
SEQ-17 Nitrogen Purging Boiler Header Condition for next step - Boiler Header N2 Vent Valve Opened Action Open Boiler Header N2 Vent Valve Timeout : 10 sec Error Error - Boiler GAS Vlv Closed - All Bnr GAS Closed - Boiler Header N2 Purge Valve Opened Open Header N2 Purge Valve Timeout : 10 sec Error & Start Start Permissive Terminate - Purge boiler hdr/bnr from monitor(Remote) - Boiler GAS Valve Close(SEQ-8,step4) OR
Wait 35 Seconds
OR
Error
Header N2 Purge Seq Failed - Header Vent Valve Open - Header N2 Purge Valve Close
End
1001854 / 0D / Page 45 of 93
Kongsberg Maritime AS
1001854 / 0D / Page 46 of 93
Kongsberg Maritime AS
Flowchart:
SEQ-19 Nitrogen Purging Boiler Header & Bnr Condition for next step - Boiler Header Vent Valve Closed Action Close Boiler Header Vent Valve Timeout : 10 sec Error Start Start Permissive Terminate - Purge boiler hdr from monitor(Remote) - Purge request from Boiler Gas Vlv Close sequence (SEQ-8 step3) OR
- Any FO Bnr On - Boiler Gas Vlv Closed - All Bnr Gas Valves Closed - Burner N2 Purge Valves Closed
&
- Bnr1 GAS Valve 1&2 Opened OR FO Bnr1 Off & - Bnr2 GAS Valve 1&2 OpenedOR FO Bnr2 Off & - Bnr3 GAS Valve 1&2 OpenedOR FO Bnr3 Off
- Open Bnr1 GAS Valves if : FO Bnr1 On - Open Bnr2 GAS Valves if : FO Bnr2 On - Open Bnr3 GAS Valves if : FO Bnr3 On Timeout : 10 sec
Error
OR
Error
Wait 25 Seconds
- Boiler Header Vent Vlv Opened - All Bnr GAS Valves Closed - Boiler N2 Valve Closed
Open Header Vent Valve After 5 sec All Bnr GAS Valve Close After 10 sec Header N2 Valve Close Timeout :30 sec
Error
Header N2 Purge Seq to Furn Failed Set - Boiler GAS Vlv Not Closed Reset Set Boiler Header/ Burner Purged Status - All Gas Bnr Valves Close - Header N2 Purge Valve Close - Header Vent Valve Open
End
1001854 / 0D / Page 47 of 93
Kongsberg Maritime AS
Master vent valves are automatically opened when: 15 sec after master gas valve close command, or Master gas valve closed limit switch is active, & Both boiler gas valves closed
Master gas valve open command is as follows: Master gas valve open order is selected from monitor. This is possible when master gas valve interlock is not active (Not master gas valve trip).
Master gas valve close command is as follows: Master gas valve close order is selected from monitor. Master gas valve interlock is active (Master gas valve trip) Both boilers gas valve interlock are active (Both boiler gas valve trip)
1001854 / 0D / Page 48 of 93
Kongsberg Maritime AS
5 BOILER CONTROL
5.1 Drum Water Level Control
The purpose of this controller is to keep the water level in boiler drum constant. This is done by controlling the feed water flow to the boiler in accordance with the steam flow from the boiler and with a correction from drum level measurement. The flow measurement and the level measurement are weighed, and then given as set point to the flow controller. In case of feed water flow transmitter is faulty, the backup controller will take over the control of the valve. The backup controller is a 2 element control based upon level measurement and steam flow measurement. The backup controller can also be activated by the operator if wanted. The level controller has following two set points and wanted set point can be selected from the IAS operator stations: Fixed level set point. Variable level set point dependent on the steam flow.
Super Htr
FI
FI
LI
High Sel
Boiler Drum
LI
Sel Switch
Feed Fwd
LC (PI)
F1
Setp
FC (PI)
Par Select
Setp
Switch
Backup Controller
LC (PI)
Feed Fwd
Setp
F2
Valve char
1001854 / 0D / Page 49 of 93
Kongsberg Maritime AS
Failsafe handling Cause Steam flow signal failure Feed water flow signal failure Level measurement signal fail Effect Steam flow value freeze Switch to backup controller Switch to safety sensor. If both control & safety sensor is failed then controller is set to manual mode, and operator must manually control the FW valve. Alarm Comments: Both sensors failed
Difference between No effect valve Command and ABU feedback > 10%
1001854 / 0D / Page 50 of 93
Kongsberg Maritime AS
Hi Sel
Steam Temp => Vlv Opening Steam Flow => Vlv Opening
Hi Sel
Cal Inp => Vlv Min Op.
Sw
Setp
PID
Feed Fwd
Hi Sel
20% 180 s
Hi Sel
FO or Dual Mode
Two steam temperature control valves are provided parallel. One is large, another is small. Small control valve is provided additionally with considering of boiler capacity. Additional small control valve is operated by fuel mode as initial plan. Action of small control valve is decided by function generator which is located between high selector and switch, as above figure.
1001854 / 0D / Page 51 of 93
Kongsberg Maritime AS
Failsafe handling Cause SH Outlet Temp Sensor Failure SH 5 pass inlet temp sensor failure Steam flow sensor failure FO flow sensor failure GAS flow sensor failure Effect Temp Controller to Manual Value frozen in last readable value Value frozen in last readable value Value frozen in last readable value Value frozen in last readable value Both sensors failed Comments: Both sensors failed
231B FO Press PI
Swit ch Swit ch
Swit ch
DO Use
PID
Setp Follow
1001854 / 0D / Page 52 of 93
Kongsberg Maritime AS
Failsafe handling Cause Atom Press signal fault FO press signal fault Effect Controller is set to Manual No effect Comments:
2bar 1bar Burner Purge SP down at Burner Purging (SEQ-4 Status 8-12)
2bar
Setp
PID
Failsafe handling Cause Purge Press signal fault Effect Controller is set to Manual Comments:
1001854 / 0D / Page 53 of 93
Kongsberg Maritime AS
Switch
Setp
PID
Failsafe handling Cause FO pump pressure signal fail MB1 FO pressure signal fail MB2 FO pressure signal fail Effect Controller is set to Manual No effect No effect If both boiler FO press signal fails then set point will be fixed. If both boiler FO press signal fails then set point will be fixed. Comments:
1001854 / 0D / Page 54 of 93
Kongsberg Maritime AS
1001854 / 0D / Page 55 of 93
Kongsberg Maritime AS
PI
PI
PI
PI
FI
FI
FI
FI
Hi Sel Hi Sel
Hi Sel
Hi Sel Hi Sel
Hi Sel
Steam Up Rate Master Setpoint Auto Set Down Set Down Bias FO Cal Input Gas Cal Input
Swit ch
Set
Trc
ed Fe
d Fw
PID
Steam-Up 0-50 Gcal/h
Set
PID
F ed Fe Trc
d w
Swit ch
Load Ratio
0-50 Gcal/h
Press => Max Load 0.00075 Gcal/kg Air Flow (kg/hr) Bias 1.1
Tracking Master : NOT (2 boiler paralell operation and FO,GAS,Air in Auto) Steam Up: FO or GAS or Air in Manual or Master Active
* * 0,5
Boiler Demand
Failsafe handling Cause MB1 steam pressure signal failed MB2 steam pressure signal failed MB1 steam flow signal failed MB2 steam flow signal failed Effect Controller is set to Manual Controller is set to Manual Value freeze Value freeze Comments: Both signals failed Both signals failed Both signals failed Both signals failed
1001854 / 0D / Page 56 of 93
Kongsberg Maritime AS
Fuel Oil Flow Controller Fuel flow controller set point is made by : Boiler master demand Actual Gas heat input. Burner min and max protection is made by set point limitation of flow controller. FO boost up function is implemented in order to decide correct FO flow in case of Gas trip.
231B FO Press 1 PI HI Sel A Swit ch
FO Press => FO Flow FG Flow => FO Flow
231B FO Press 2 PI
Master Cal Demand Gas Cal Input 0 FO Boost Up Order Swit ch & OR 2nd FO Ign Set Req 3rd FO Ign Set Req Dual Mode
Lo Sel
FO Cal Value
No Of FO Bnr
X A PID
Swit ch Hi Sel
FO Flow FO Cal Inp X FO Cal Value FO Boost Up Order PID Lo Sel Swit ch FO Recirc Vlv Opened FO Ignition , FO FO Ignition, Dual 1bnr FO Ignition, Dual 2bnr FO Ignition, Dual 3bnr
Setp
Swit ch
Min FO Flow 1 Bnr FO Min FO Flow 2 Bnr FO Min FO Flow 3 Bnr FO Min FO Flow 1 Bnr Dual Min FO Flow 2 Bnr Dual Min FO Flow 3 Bnr Dual Min FO Cal Inp
FO Cal Value
1001854 / 0D / Page 57 of 93
Kongsberg Maritime AS
Failsafe handling Cause FO press signal failed Gas press signal failed Effect Manual mode No effect Comments: Both sensor failed
Fuel Gas Flow Controller Gas Flow is measured by differential press transmitter for Gas flow input (differential pressure between burner/Hdr), BOG pressure and BOG temperature. Controller set point is set from boiler master. Set point is defined as boiler master FO minimum flow. A separate minimum controller is provided in order to maintain Gas minimum flow FO boost up function is implemented in order to keep gas supply steady during FO ignition when master gas valve trip is activated.
1001854 / 0D / Page 58 of 93
Kongsberg Maritime AS
No Of Gas Bnrs
Swit ch OR
& Lo Sel
0
OR
2nd FO Ign Set Req 3rd FO Ign Set Req Dual Mode
Swit ch
/
To Air Flow Control To Fuel Oil Flow Control With Up/Dwn Ramp Flt
Swit ch Hi Sel
X
Gas Cal Value
Swit ch
Min Gas Flow 2 Bnr Min Gas Flow 3 Bnr Min Gas Flow At Bnr Inc
PID
Flow Controller
Setp
PID
Hi Sel Swit ch
Gas Shut Vlv Closed Gas Ignition, 1bnr, Free Flow Gas Ignition, 2bnr, Free Flow
FO Boost Up Order
Swit ch
Gas Ignition, 3bnr, Free Flow Gas Ignition, 1bnr, LD Run Gas Ignition, 2bnr, LD Run Gas Ignition, 3bnr, LD Run
1001854 / 0D / Page 59 of 93
Kongsberg Maritime AS
Failsafe handling Cause Gas press signal failed BOG press signal failed BOG temp signal failed GAS Flow signal failed Effect Switch to flow control No effect No effect Switch to pressure control Comments:
Air Flow Controller The set point for the air controller is calculated by the total calorie input (FO flow + Gas flow) multiplied by an air ratio. A feed fwd from boiler master demand is used in order to quickly response to load changes. The air ratio is automatically adjusted by an O2 controller. The O2 controller set point is variable with the boiler load. If wanted the air/fuel ratio can be adjusted manually. The air controller is built to lead during load increase.
1001854 / 0D / Page 60 of 93
Kongsberg Maritime AS
GAS Flow
FO Flow
Burner Load
Flue Gas O2 O2
Air Flow PI
17.47
14
+ A X Fuel/Air Ratio Set 0.5 - 1.5 Soot Blow Running 1.1 Air Bias ( Bnr Seq) 1.05
Excess Ratio
Calc
mbar => Kg/h Setp
PID
Range 0.9-1.1 Setp
X Not Man Zone Steam Flow > 80% 3 Bnr Run &
Fo llo w1
.0
PID
Sw i tch X
Vane Char
Sw i tch +
Boiler Master
Note:
O2 trim control is activated when the following conditions are established: Steam flow > 80% & 3 burners firing.
Failsafe handling Cause Air flow sensors failed FO press signal failed Gas press signal failed O2 Sensor failed Effect Air flow controller to manual No effect No effect O2 trim is bypassed Comments: Both sensors failed
1001854 / 0D / Page 61 of 93
Kongsberg Maritime AS
1001854 / 0D / Page 62 of 93
Kongsberg Maritime AS
FI Hi Sel
&
Not
MB1 Min FO Flow MB2 Min FO Flow Rec BOG 0-130 t/h Load Limit
Lo Sel
Swit ch
PID
PID
Set
BOG Controller
MB1 FG Vlv Pos MB2 FG Vlv Pos Max FG Vlv Pos 95%
Hi Sel
t Se
MT Trip
To IAS for Spray Vlv Control 331B Dump C/V #1 332B Dump C/V #2
90
Du m p 1
Du m p 2
80
70
60
50 40
30
20
1001854 / 0D / Page 63 of 93
Kongsberg Maritime AS
Dump Piston Valve. Prior to steam dump control valves opening, the dump piston valve must be opened. This logic is calculated within the ABC by using dump control loop internal variables. In addition input from MT RCS is used. IAS calculates a dump available signal. If this signal is not present the dump piston valve will shut down.
Dump Controller: Set - Pv < 0.5 bar Dump controller output > 1% MT manovering zone MT Trip Off Delay 3min Dump Piston Vlv Open Order
&
OR
Failsafe handling Cause Steam press sensors failed Steam flow sensors failed MB1 Gas control vlv pos feedback failed MB2 Gas control vlv pos feedback failed MB1 FO flow signal failed MB2 FO flow signal failed Effect Controllers is set to Manual No effect No effect No effect No effect No effect Comments: 4 sensors failed
1001854 / 0D / Page 64 of 93
Kongsberg Maritime AS
1001854 / 0D / Page 65 of 93
Kongsberg Maritime AS
1001854 / 0D / Page 66 of 93
Kongsberg Maritime AS
Opened
Closed
&
OR
&
Timer ON 3 min
1001854 / 0D / Page 67 of 93
Kongsberg Maritime AS
+
No.2 Blr FO Flow No.1 Blr Gas Mode No.2 Blr Gas Mode
LSE
Set 1200kg/hr Reset 1700 kg/hr
OR
1001854 / 0D / Page 68 of 93
Kongsberg Maritime AS
1001854 / 0D / Page 69 of 93
Kongsberg Maritime AS
MT Trip
10 s
MT Slow dow n
10 s
MT Program Interlock
10 s
MT Slow dow n
Main Boiler 2 Drum Water Level Transmitter CompHi 220mm CompHi 200mm CompHi 180mm CompLo -200mm
10 s
MT Trip
10 s
MT Slow dow n
10 s
MT Program Interlock
10 s
MT Slow dow n
Boiler Com m on MB1 Logick Boiler Firing & Both Boiler Trip
&
OR
MB2 Logick
Boiler Firing
&
1001854 / 0D / Page 70 of 93
Kongsberg Maritime AS
6 BOILER TRIP
The trip system is divided into five different categories. FO trip. Boiler trip. Boiler GAS trip. Master GAS trip. Burner flame fail trip.
Once the trip circuit is activated a holding circuit is activated and corresponding trip cause is flickering. Acknowledge button must be operated in order to confirm the trip cause, corresponding lamp is then steady lit. Trip circuit is still active. Acknowledge can be done from IAS or BGB whichever location is in command. When trip cause is acknowledged and trip cause is brought to normal, then trip can be reset by operating the respective system stop pushbutton. Trip circuit is de-activated. In case drum water level safety transmitter is faulty the control sensor can be selected for safety functions. This operation must be manually initiated by the operator. FO Trip. In case of FO trip condition is activated the FO supply to the boiler is tripped. Cause Atomizing steam press LL (3bar) FO temp LL (have bypass switch) (80 deg/C) FO Press LL (1bar) FO Pump Stop Fuel/Atomize Valve Abnormal Action - Boiler FO Shut Vlv Close - No1 burner FO vlv1&2 Close - No2 burner FO vlv1&2 Close - No3 burner FO vlv1&2 Close Reset Acknowledge pushbutton and Boiler FO shutoff vlv close pushbutton
1001854 / 0D / Page 71 of 93
Kongsberg Maritime AS
Logic Diagram.
Atm Steam Press LL FO Temp LL FO Temp Bypass Sw itch & FO Trip &
FO Press LL &
OR
FO Pump Stop Any FO Bnr On Emergency Mode Fuel/Atomiz Valve Abnormal &
FO Trip OR Boiler trip Control position IAS IAS Blr FO Shutoff Vlv Close Push button Control position BGB BGB Blr FO Shutoff Vlv Close Push button & OR &
Set Reset RS
BoilerFO Shutoff Vlv Shutdow n Order Bnr1 FO Vlv1&2 Shutdow n Order Bnr2 FO Vlv1&2 Shutdow n Order Bnr3 FO Vlv1&2 Shutdow n Order
1001854 / 0D / Page 72 of 93
Kongsberg Maritime AS
Boiler Trip. In case boiler trip condition occur is both FO and Gas system is tripped. Cause Drum water level HH (+240mm + 10s) by analogue sensor Drum water level LL (-240mm) by switch OR Drum water level LL (-240mm + 5s) by analogue sensor FDF stop All burner flame fail Emergency manual trip ECR Emergency manual trip BGB Main steam temp H (545deg/c) by analogue sensor Acknowledge pushbutton and Boiler Gas vlv close push-button reset Gas trip. Action - Activate FO trip - Activate Gas trip Reset Acknowledge pushbutton and Boiler FO shutoff vlv close pushbutton resets FO trip
1001854 / 0D / Page 73 of 93
Kongsberg Maritime AS
10 s
5s
Drum Water Level LL Float Sw itch No1 FD Fan Run Stby Fan Mode On Stby FD Fan Run High or Low Stby FD Fan Air Dmp OK Stby FD Fan Selected All Bnr Flame Fail Emerg Manu Trip ECR Emerg Manu Trip BGB Steam Temp Transmitter CompHi 545C & &
Boiler Gas Trip. In case of Gas trip condition is activated the Gas supply to the boiler is tripped. Cause BOG Press L (7mbar) BOG Press H (736mbar) Boiler Trip Condition Master Gas Valve Trip On + 15s Action - Boiler Hdr Vent Vlv Open - Boiler Gas Shut Vlv Close - No1 burner Gas vlv1&2 Close - No2 burner Gas vlv1&2 Close - No3 burner Gas vlv1&2 Close Reset Acknowledge pushbutton and Boiler Gas shutoff valve close pushbutton
1001854 / 0D / Page 74 of 93
Kongsberg Maritime AS
&
&
Boiler Trip On
15 s
Set Reset RS
Boiler Vent vlv Open Order Boiler GAS Vlv Shutdow n Order Bnr1 GAS Vlv1&2 Shutdow n Order Bnr2 GAS Vlv1&2 Shutdow n Order Bnr3 GAS Vlv1&2 Shutdow n Order
Master GAS Valve Trip. In case of Master GAS trip condition is activated the GAS supply to both boilers is tripped. Simultaneously FO boost up order is sent to each boiler. Cause E/R Vent Fan Failure Gas Duct Exh Fan Stop Gas leak detected Fire Detected BOG Temp LL (5deg/c) Master GAS Vlv Manu Trip Vapor Hdr Press LL BOG Htr Abnormal Master Gas Close Push Button Both Boiler trip Action - Master GAS Vlv Shutdown - Master N2 Vent Vlv Oppen Reset Acknowledge pushbutton and Master GAS Vlv close push-button
1001854 / 0D / Page 75 of 93
Kongsberg Maritime AS
E/R Vent Fan Failure Gas Duct Exh Fan Stop Gas Leak Detected Fire detected BOG Temp LL Master Gas Vlv Manu Trip (ECR) Master Gas Vlv Manu Trip (BGB) Vapour Hdr Press LL BOG Htr Abnormal Master Gas Vlv Close PB Master GAS Vlv Trip OR OR
On-delay
10 s
FO Boost Up Order
Both Boiler Trip Both Blr GAS Vlv's Closed LS GAS Master Vlv Trip GAS Master Vlv Close Pushbutton Set Reset RS Master Vent vlv Open Order Master GAS Vlv Shutdown Order
1001854 / 0D / Page 76 of 93
Kongsberg Maritime AS
Burner Flame Fail. In case flame is lost during burner firing, the burner FO and GAS supply is tripped.
Control Mode Manual Control Position IAS Control Position BGB Base Bnr IR 1&2 Failed Base Bnr UV1&2 Failed & IAS Base Bnr OFF PB & Set Reset RS Base Bnr Flame1 Fail Base FO Bnr Valve Close Base GAS Bnr Valve Close Base Bnr Atmise Valve Close Base Bnr Air Reg Close
OR
& BGB Base Bnr OFF PB No.2 Bnr IR1&2 Failed No.2 Bnr UV1&2 Failed & IAS No.2 Bnr OFF PB & Set Reset RS No.2 Bnr Flame1 Fail No.2 FO Bnr Valve Close No.2 GAS Bnr Valve Close No.2 Bnr Atmise Valve Close No.2 Bnr Air Reg Close
OR
& BGB No.2 Bnr OFF PB No.3 Bnr IR1&2 Failed No.3 Bnr UV1&2 Failed & IAS No.3 Bnr OFF PB & Set Reset RS No.3 Bnr Flame1 Fail No.3 FO Bnr Valve Close No.3 GAS Bnr Valve Close No.3 Bnr Atmise Valve Close No.3 Bnr Air Reg Close
OR
&
OR
&
1001854 / 0D / Page 77 of 93
Kongsberg Maritime AS
Description
Type
Function
Orginator
By-pass Condition No1 or No2 Emerg Mode Common Emerg Mode AC 220V Source DC 24V Source MB1 + MB2 MB1 + MB2 MB1 + MB2 MB1 + MB2 Lamp Lamp Lamp Lamp Switch on BGB for selection of Emergency Mode Switch on BGB for selection of Emergency Mode Lamp on BGB Lamp on BGB BGB (by MHI) BGB (by MHI) BGB (by MHI) BGB (by MHI)
NoX Burner NoX Gas BNR On MB1 x 3 + MB2 x 3 Switch/Lamp Swich: Starts GAS Burner when Local Contr Position & manual mode. Lamp: - Flicker during start seq, - Fast Flicker when start error - Steady when burner is On NoX Gas BNR Off MB1 x 3 + MB2 x 3 Switch/Lamp Swich: Stops GAS Burner when Local Contr Position & manual mode. Also reset of start/stop error Lamp: - Flicker during stopt seq, - Fast Flicker when stopt error - Steady when burner is On FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
1001854 / 0D / Page 78 of 93
Kongsberg Maritime AS
Type
Function
Switch/Lamp Swich: Starts FO Burner when Local Contr Position & manual mode. Lamp: - Flicker during start seq, - Fast Flicker when start error - Steady when burner is On
MB1 x 3 + MB2 x 3
Switch/Lamp Swich: Stops FO Burner when Local Contr Position & manual mode. Also reset of start/stop error Lamp: - Flicker during stopt seq, - Fast Flicker when stopt error - Steady when burner is On
FS-10(MB1), FS-11(MB2)
Flame Signal
MB1 x 2 + MB2 x 2
Indicator
Indicator
FO Shut V/V Open MB1 + MB2 Switch/Lamp Swich: Send open command to FO shut valve Lamp: - Flicker during open time, - Fast Flicker if open failed - Steady when valve is open Close MB1 + MB2 Switch/Lamp Swich: Send close command to FO shut valve, also used FS-10(MB1), for FO/Boiler trip reset Lamp: - Flicker during close time, - Fast Flicker if close failed - Steady when valve is closed FS-11(MB2) FS-10(MB1), FS-11(MB2)
Furnace Purge Request MB1 + MB2 Switch/Lamp Switch : Lamp: Activates furnace purge sequence Switch On FS-10(MB1), FS-11(MB2) Lamp: BGB(by MHI) In Progress MB1 + MB2 Lamp Lamp On: Furnace purge in progress FS-10(MB1), FS-11(MB2) Complete MB1 + MB2 Lamp Lamp On: Furnace purge compleate OR Purge Status FS-10(MB1),
1001854 / 0D / Page 79 of 93
Kongsberg Maritime AS
Description
Type
Function
Orginator FS-11(MB2)
BMS Position BGB Manual MB1 + MB2 Switch/Lamp Switch: Change burner operation to BGB location Lamp: Burner operation at BGB On IAS MB1 + MB2 Switch/Lamp Switch: Change burner operation to IAS Lamp Burner operation at IAS On FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
Alarm Boiler Trip MB1 + MB2 Lamp Boiler trip active or nor reset FS-10(MB1), FS-11(MB2) Atm Press Low MB1 + MB2 Lamp Atm press low active FS-10(MB1), FS-11(MB2) FO Press Low MB1 + MB2 Lamp FO press low active FS-10(MB1), FS-11(MB2) Manual trip MB1 + MB2 Lamp Boiler Manual Trip active FS-10(MB1), FS-11(MB2)
ABC Position BGB MB1 + MB2 Switch/Lamp Switch: Change control loop operation to BGB location Lamp: Control loop operation at BGB On IAS MB1 + MB2 Switch/Lamp Switch: Change control loop operation to IAS Lamp Control loop operation at IAS On FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
GAS Firing
MB1 + MB2
Lamp
FS-10(MB1), FS-11(MB2)
Feed water motor valve Open MB1 + MB2 Switch/Lamp Switch: Send open command to feed water motor valve control panel. Lamp: - Flicker during open time - Fast flicker if opened failed FS-10(MB1), FS-11(MB2)
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Kongsberg Maritime AS
Description
Type
Function
Orginator
Aux Feed Water Pump Start Common Switch Switch: Send start command to group starter panel via IAS. Stop Common Switch Switch: Send stop command to group starter panel via IAS. Run Common Switch Lamp: Steady when motor is Running. FS12,(Com) FS12,(Com) FS12,(Com)
Seal Air Fan Run (No1/2) Common Lamp Lamp: Steady when fan is Running. FS12,(Com)
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Kongsberg Maritime AS
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Kongsberg Maritime AS
ABC Position
IAS BGB OR Emerg mode Set Reset RS Not IAS BGB
Manual/Auto Selection
ABC Position "BGB" & BGB A & OR & OR Set Reset RS Not Auto Manual
&
PID
c Tr e lu Va
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Kongsberg Maritime AS
Note : If burner does not ignite by the above process, repeat operation from the above 3). Note : If drum water level low-low with float switch is detected, acknowledge button on BGB should be depressed.
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Kongsberg Maritime AS
After selection of operation mode the sequence can by started. Following sequence selections are prepared: SEQ START ECO START Bypass Function Bypass function is performed manually or automatically. Manual function is active by selecting the corresponding bypass push buttons of IAS. Auto function is as follows. When "SEQ START" or "ECO START" function is running, if trouble occurs then corresponding soot blower is bypassed automatically.
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Kongsberg Maritime AS
Emergency retract If long soot blower forward sequence is active then the sequence is stopped. And the long soot blower retract sequence is stated. If long soot blower is not active or complete then "steam supply valve" is closed and "drain valve" is opened. If rotary soot blower sequence is active then the sequence is continued to the end position. Local Control. Local control is active by changing the control location from IAS to Local. Then start order will be active by depressing the "BOTH BLR" push button of IAS. After depressing the "BOTH BLR" push button of IAS, "steam supply valve" open and "drain valve" close. Operator can start the soot blower by depressing the corresponding Soot Blower push button. The subsequences Long Soot Blower and Rotary Soot Blower as described below is activated directly by the operator.
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Kongsberg Maritime AS
Action Start Fwd Timeout : 5 sec Error - Staem Valve Open - Not Emerency Retract On - Not Reverse Position - Not Steam Press Low - Not Emergency - Not Motor Overload - Not Reverse Run if Auto Seq - Boiler Load < 50 %
Error
&
Error - Emergency Retract ON - Steam press low & 30 Sec After Vlv Open - Steam supply valve abnormal if Auto Seq OR - Boiler trip - Auto Seq Fail - Motor Overload
Error
- Reset Run Fwd Order - Set Rev Order if not stop position - Set Alarm - Set Bypass if Auto Seq
End
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Kongsberg Maritime AS
Start
- Start Req from Soot Blow Auto Seq - Start Req from Local.
OR
Condition for next step - Blower Running ON & - Stop Position OFF
&
OR
End
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Kongsberg Maritime AS
Action Open Steam Vlv Timeout : 40 sec Close Other Blr Drain Valve Timeout : 10 sec Error - Control position IAS - No1 or No2 Boiler Select - Not ECO START - Not other BLR SEQ START - Not other BLR ECO START - Not motor over load - Not Soot Blower abnormal - Not Emergency retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
Error
&
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec Start L1 If not Bypass ON Timeout : 2 sec Wait, L1 blowing Timeout : 500 sec Start L2 If not Bypass ON Timeout : 2 sec Wait, L2 blowing Timeout : 500 sec Start R1 If not Bypass ON Timeout : 2 sec Wait, R1 blowing Timeout : 60 sec Start R2 If not Bypass ON Timeout : 2 sec Wait, R2 blowing Timeout : 60 sec Start R3 If not Bypass ON Timeout : 2 sec Wait, R3 blowing Timeout : 60 sec Start R4 If not Bypass ON Timeout : 2 sec Wait, R4 blowing Timeout : 60 sec Start R5 If not Bypass ON Timeout : 2 sec Wait, R5 blowing Timeout : 60 sec Start R6 If not Bypass ON Timeout : 2 sec Wait, R6 blowing Timeout : 60 sec Close Steam Valve if all long blower in normal stop position & Open Drain Vlv 1&2 Timeout : 10 sec End
Error
- L1 Seq Run OR - Bypass ON - L1 Seq Run for 364 sec OR - L1 Seq Not Run - L2 Seq Run OR - Bypass ON - L2 Seq Run for 388 sec OR - L2 Seq Not Run - R1 Seq Run OR - Bypass ON - R1 Seq Run for 38 sec OR - R1 Seq Not Run - R2 Seq Run OR - Bypass ON - R2 Seq Run for 38 sec OR - R2 Seq Not Run - R3 Seq Run OR - Bypass ON - R3 Seq Run for 18 sec OR - R3 Seq Not Run - R4 Seq Run OR - Bypass ON - R4 Seq Run for 38 sec OR - R4 Seq Not Run - R5 Seq Run OR - Bypass ON - R5 Seq Run for 38 sec OR - R5 Seq Not Run - R6 Seq Run OR - Bypass ON
Bypass
Error
- Emergency Retract ON - Steam press low & 30 sec after eam valve open - Steam supply valve abnormal - Boiler Trip - AC 440V Failure
OR
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
Error
Bypass
- Terminate all soot blower sub sequences - Close steam Vlv if all long blower in normal stop position - Open No1 MB Drain Vlv
Error
- Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
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Kongsberg Maritime AS
Action Open Steam Vlv Timeout : 40 sec Close No.2 Blr Drain Valve Timeout : 10 sec Error - Control position IAS - Both Boiler Select - Not ECO START - Not other BLR SEQ START - Not other BLR ECO START - Not motor over load - Not Soot Blower abnormal - Not Emergency retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
Error
&
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No1 Boiler Blower Sequence L1,L2,R1,R2,R3,R4,R5,R6 Open No.2 Boiler Drain Vlv Timeout: 10 sec
Error
Error
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam supply valve abnormal - Boiler trip - AC 440V Failure
OR
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No2 Boiler Blower Sequence L1,L2,R1,R2,R3,R4,R5,R6
Error
- Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
Close Steam Valve if all long blower in normal stop position & Open Drain Vlv 1 & 2 Timeout : 10 sec
- Terminate all soot blower sub sequences Error - Close steam Vlv if all long blower in normal stop position - Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
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Kongsberg Maritime AS
Action Open Steam Vlv Timeout : 40 sec Close Other Boiler Drain Valve Timeout : 10 sec Error - Control position IAS - Not SEQ START - Not other Blr SEQ START - Not other Blr ECO START - Not moter over load - Not soot blower abnormal - Not Emergency Retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
Error
&
Timer 180s
- Steam Press OK
Check Steam Press OK Timeout : 2 sec Start R3 If not Bypass ON Timeout : 2 sec Wait, R3 blowing Timeout : 60 sec Start R4 If not Bypass ON Timeout : 2 sec Wait, R4 blowing Timeout : 60 sec Start R5 If not Bypass ON Timeout : 2 sec Wait, R5 blowing Timeout : 60 sec Start R6 If not Bypass ON Timeout : 310 sec Wait, R6 blowing Timeout : 60 sec Close Steam Valve & Open Drain Vlv 1 & 2 Timeout : 10 sec
Error
- R3 Seq Run OR - Bypass ON - R3 Seq Run for 18 sec OR - R3 Seq Not Run - R4 Seq Run OR - Bypass ON - R4 Seq Run for 38 sec OR - R4 Seq Not Run - R5 Seq Run OR - Bypass ON - R5 Seq Run for 38 sec OR - R5 Seq Not Run - R6 Seq Run OR - Bypass ON
Bypass
Error
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam supply valve abnormal - Boiler Trip - AC440V Failure
OR
Bypass
Error
Bypass
Error
Bypass
Error
- Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
Error
- Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
1001854 / 0D / Page 91 of 93
Kongsberg Maritime AS
Action Open Steam Vlv Timeout : 40 sec Close No.2 Blr Drain Valve Timeout : 10 sec Error - Control position IAS - Not ECO START - Not other BLR SEQ START - Not other BLR ECO START - Not motor over load - Not Soot Blower abnormal - Not Emergency retract ON - Not Steam supply valve abnormal - Boiler Load < 50 %
Error
&
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No1 Boiler Blower Sequence R3,R4,R5,R6 Open No.2 Boiler Drain Vlv Timeout: 10 sec
Error
Error
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam supply valve abnormal - Boiler Trip - AC 440V Failure
OR
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec No2 Boiler Blower Sequence R3,R4,R5,R6
Error
- Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
Close Steam Valve & Open Drain Vlv 1 & 2 Timeout : 10 sec
- Terminate all soot blower sub sequences Error - Close steam Vlv - Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
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Kongsberg Maritime AS
9 ATTACHMENTS
- Parameter List. (will be issued later) - ABC Operator Manual. (will be issued later)
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