OPERATING INSTRUCTION

System: Water Lance-Type Blower (WLB)

Job No Ha 19871 Karsten Kleye

Plant: Neyveli Power Plant, Thermal Station II, Dept.: SPF
Boiler I - VII India
Customer: ABB-Alstom Power Combustion GmbH Telephone : 00 49
(0) 281 815-0
Date: August, 2000 14

The following plant components are selected and registered by the control system:
3 motorised shut off valves
1 water booster pump
1 pressure measuring points in the main line
4 water lance-type blowers with
1 blowing valve and 1 pressure measuring point each blower

There are two places of operation:

- control panel PCS 090 in the control desk of the control room
- local control point on each blower.

On the control panel the following modes of operation can be chosen:

- automatic operation.
- manual - local operation

1. Local Operation

On the PCS 090 you must select the mode manual -local. To this the key switch must be switched at the
local control box in position manual.
When the plant is changed over to LOCAL operation, the blowing lance can be moved in all directions by
means of the LOCAL control points.
Only one single blower can be operated.
The blower on which the release was actuated first, has priority.
If during LOCAL operation and the key-switch SO1 in the switch cabinet is in position 2 (test operation),
the solenoid valve opens on actuation of a direction push button .

Note! During LOCAL operation no final positions are monitored.

Do not move against the mechanical stops.

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2. Manual Operation

On the PCS 090 you must select the mode manual -local.
Then can you one after the other started all part figures of all blowers in any order.

Release Conditions :
Water Sootblower Pump 1 or 2 RUNNING

Suction valve open for Signal only Q 23.0 = on

Water Pump on **
Discharge valve open
Bypass valve closed
Pressure Main Line > 14 bar **
No Collective Trouble
for Signal only Q 23.3 = on
for Signal only Q 23.2 = on
for Signal only Q 23.1 = on
for Signal only Q 23.4 = on
for Signal only Q 23.5 = on

** this signals can be bypassed with the key switch TESTOPERATION in position 2

3. Automatic Operation

The automatic operation is used for cleaning the boiler by means of the system in an automatic sequence.
Each WLB sweeps its area to be cleaned in six different part figures. By input of the part figures numbers
1,2,3,4,5 or 6 it is possible to decide on the control panel which part figures is selected in the automatic
program.
The input of the part figures number 0 causes that all part figures (1-6) are selected one after the other.
Input: number and ENTER

Moreover, it can be decided at the control device which blowers shall participate in the automatic
program.
For this purpose the participation can be switched on and off for each blower.
( IS PRESELECTED or NOT PRESELECTED ).
Blowers not preselected are skipped in the program sequence.

Before you can start the automatic program,

the following starting position must be reached :

Release Conditions :
Water Sootblower Pump 1 or 2 RUNNING

Suction valve open for Signal only Q 23.0 = on

Water Pump on **
Discharge valve open
Bypass valve closed
Pressure Main Line > 14 bar **
No Collective Trouble
for Signal only Q 23.3 = on
for Signal only Q 23.2 = on
for Signal only Q 23.1 = on
for Signal only Q 23.4 = on
for Signal only Q 23.5 = on

** this signals can be bypassed with the key switch TESTOPERATION in position 2

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After starting the automatic program the following steps are carried out automatically:

1.) Suction valve of water supply system will open

2.) Booster pump on
3.) Discharge valve of water supply system will open and bypass valve will closed
When the maximum limit value on the pressure gauge in the main line is exceeded, the pressure
release is put and:

4.) WLB 1 moves to the reference point

5.) WLB 1 moves to the starting point
6.) WLB 1 moves along the first part figures (blowing valve will open at the beginning and will
closed at the end).
7.) WLB 1 moves to the reference point
8.) WLB 1 moves into basic position
9.) WLB 1 moves along patterns 2 to 6 in the same order (point 4-9)
10.) WLB 2 , 3 and 4 moves as WLB 1
11.) Booster pump is switched off.
12.) Suction valve and discharge valve of water supply system will closed and bypass valve will open

In this example all WLBs are selected ( IS PRESELECTED ) and the blowing figures 0 are preselected.
( All part figures 1 - 6 )

If a failure occurs during the operation of one WLB, the program is continued with the next WLB after
elimination and acknowledgement of the failure.

4. Test Operation

A key-operated switch is installed in the control cabinet.

This switch has the positions
1- real operation
2- test operation.

When it is switched to test operation, the unit can be tested without blowing medium being supplied. First
of all this operation serves for commissioning the blowers without water. During test operation the
solenoid valves of the WLBs also open when in LOCAL operation a directional push button is actuated.
Test operation blocks the automatic switching-on of the booster pump. When a pressure is registered
during test operation, the test function is cancelled.

5. Failures

All failure indications are interrogated in 1-second cycles and indicated, if available.

LANCE 1 LOCAL INSTANTLY OFF-SWITCH ACTUATED

LANCE 2 LOCAL INSTANTLY OFF-SWITCH ACTUATED
LANCE 3 LOCAL INSTANTLY OFF-SWITCH ACTUATED
LANCE 4 LOCAL INSTANTLY OFF-SWITCH ACTUATED

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INSTANTLY OFF-SWITCH on one of the WLBs was actuated
( I 0.7 and/or I 10.4, I 11.1, I 11.6 is off ).

CIRCUIT BREAKER TRIPPED

circuit breaker F 011 or F 012 tripped ( I 9.1 is off)

BLOWING VALVES NOT CLOSED

5 seconds after closing the blowing valve ( Q 12.0 off ) pressure is still available,
e.g. the valve closes too slowly or not at all.

Pressure after blowing valve is greater min ( 1.2 bar )

back indication blowing valve closed is not available

WLB 1 I 0.4 and I 0.5 WLB 2 I 10.1 and I 10.2

WLB 3 I 10.6 and I 10.7 WLB 4 I 11.3 and I 11.4
are not on.

BLOWING VALVE NOT OPENED

8 seconds after opening the blowing valve ( Q12.0 on ) limit value + min ( 12 bar ) is not available,
or the valve does not back-indicate

WLB 1 I 0.4 and I 0.5 WLB 2 I 10.1 and I 10.2

WLB 3 I 10.6 and I 10.7 WLB 4 I 11.3 and I 11.4

are not off.

OVERCURRENT BLOWING VALVES

The protective switch for the blowing valves F02 released I 9.2 does not light up.

IMPULSE TROUBLE VERTICAL

- A motor of one WLB was selected ( Q 13.0 or Q 13.2 on ), without counting pulses being measured
( no pulses on I 0.0 ) .
- The WLB moved to a stop.
- Cardan joints and/or blowing tube guide difficult to move.
- Pulse generator defective.
- Frequency converter does not operate, green LED at the frequency converter is switched on at Q13.0
or Q13.2 not from flashing light to continuous light.

IMPULSE TROUBLE HORIZONTAL

As above, however, in horizontal direction.

( Q 13.5 or Q 13.7 on), without counting pulses being measured (no pulses to I 0.1).

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FREQUENCY CONVERTER VERTICAL TROUBLE

The frequency converter for the vertical travelling direction failed (red LED at the frequency converter
lights up). Eliminate failure by switching off and on the main switch.

FREQUENCY CONVERTER HORIZONTAL TROUBLE

As above, however, in horizontal direction.

TROUBLE MAIN PRESSURE

this trouble becomes if:

- the solenoid valve open and the water pressure in the main line is for 5 seconds not higher 14 bar and
not deeper 32 bar.
- the water pump is in operation and the bypass valve is close and water pressure isn't higher than 14 bar
in 8 seconds.

PUMP ON & BLOWING VALVE NOT OPENED IN TIME

this trouble comes if:

- the solenoid valve and the bypass valve are not open for longer than 5 minutes.

The failure indications BLOWING VALVE NOT CLOSED and / or TROUBLE MAIN PRESSURE
will stopped the Program.

The failure indications BLOWING VALVE NOT CLOSED and / or PUMP ON & BLOWING
VALVE NOT OPENED IN TIME or the suction valve isn't open, switch off the booster pump and
close the valves of the water supply system.

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6. Operating Unit

The following push buttons on the operating unit are important:

F1 mode OPERATE
F2 mode OBSERVE
F3 mode FAILURE INFORMATION
F4 without importance
F5 RELEASE ( is required together with F7 and F8 )
F6 ACKNOWLEDGE FAILURE
F7 I ( on / open / start )
F8 0 off / close / stop )

0, 1, 2, 3, 4, 5, 6 for the input of the required part figures (followed by ENTER)

The partial pattern 0 means that the blower moves along all blowing figures ( 1 - 6 ) one after the other.
When the red LED ( ERROR ) lights up at the operating unit PCS 090, the communication between
control system and operating unit can be restored by switching the control system once from STOP to
RUN.

7. Handover of Potential-Free Contacts

X 5.1 S5 control system in failure K0201 ground contact

.2 normally closed contact
.3 normally open contact

X 5.4 valves open booster pump on K0202 ground contact

.5 normally closed contact
.6 normally open contact
.7 ground contact
.8 normally closed contact
.9 normally open contact

X 5.10 program finished to stop old water pump K0203 ground contact
.11 normally closed contact
.12 normally open contact

X 5.13 trouble horn K0204 ground contact

.14 normally closed contact
.15 normally open contact

the relay trouble horn will switch to on 5 times when an trouble is active.
after trouble reset the relay is off.

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MENU - LOCAL

OPERATION MODE NOT PRESELECTED

"LOCAL" or IS PRESELECTED
SUCTION VALVE TROUBLE
or OPENING
or OPEN
or CLOSING
or CLOSE
or NO LIMIT SWITCH IS ON

BYPASS VALVE TROUBLE

or OPENING
or OPEN
or CLOSING
or CLOSE
or NO LIMIT SWITCH IS ON
WATER PUMP NOT IN OPERATION
or IN TROUBLE
or IN OPERATION
DISCHARGE VALVE TROUBLE
or OPENING
or OPEN
or CLOSING
or CLOSE
or NO LIMIT SWITCH IS ON
MANUAL START WATERLANCE: * PART FIGURE: **

NOT IN OPERATION F5 + F7 = ON
or VALVES OPENING
or WATER PUMP IN OPERATION
or PART FIGURE 1 IN OPERATION
or PART FIGURE 2 IN OPERATION
or PART FIGURE 3 IN OPERATION
or PART FIGURE 4 IN OPERATION
or PART FIGURE 5 IN OPERATION
or PART FIGURE 6 IN OPERATION
or VALVES CLOSING
or WATER PUMP NO OPERATION
The valves driven and the Booster pump can be switched on in this menu.
The part figures of the water lance blowers can be started one by one in this menu.
* number of water lance blower
** number of part figure

In the local mode the water lance blowers can be operated with the push buttons in the local control box.
To this the key switch must be switched at the local control box in position manual.

MENU AUTOMATIC

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AUTOMATIC NOT PRESELECTED
OPERATION IS PRESELECTED

<-START/STOP AUTOMATIC REL ON OFF

WATERLANCE 1 NOT PRESELECTED

IS PRESELECTED
PART FIGURE NOMINAL ** ACTUAL **
WATERLANCE 2 NOT PRESELECTED
IS PRESELECTED
PART FIGURE NOMINAL ** ACTUAL **
WATERLANCE 3 NOT PRESELECTED
IS PRESELECTED
PART FIGURE NOMINAL ** ACTUAL **
WATERLANCE 4 NOT PRESELECTED
IS PRESELECTED
PART FIGURE NOMINAL ** ACTUAL **
AUTOMATIC NO RELEASE TO START
or PROGRAM READY TO START
or PROGRAM READY TO Reset
or PROGRAM RUNNING
or PROGRAM IS STOPPED
or PROGRAM FINISHED

<- BACK push F5 + F7 to start

or NOT ALL LOCAL BOX IN AUTOMATIC
or WLB NOT SELECTED
or AUTOMATIC MODE NOT SELECTED
or push F5 + F8 to stop

In this menu it is possible to select everything for the automatic sequence.

For PRESELECTION use F5 + F7 for ON and F5 + F8 for OFF.
For the PART FIGURE push 0,1,2,3,4,5 or 6 and ENTER.

** number of part figure

MENU OBSERVE

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WATERLANCE ** NOT IN OPERATION
or VALVES OPENING
or WATER PUMP IN OPERATION
or PART FIGURE * IN OPERATION
or VALVES CLOSING
or WATER PUMP NO OPERATION

SWITCH IN POS. "WITHOUT WATER" (or) **.* bar

PRESSURE MAIN LINE (or) **.* bar
PRESSURE AFTER BLOWING VALVE xx.x bar

In this menu it is possible to observe the system after starting the automatic sequence.
The system will this menu switched on automatically, whenever the automatic program was started.

This menu can be switched on also with the key F 2.

** number of blower
* number of part figure
**.* measurment indication pressure main line
xx.x measurment indication after blowing valve of the in operation situated waterlance

MENU TROUBLE INFORMATION

Trouble reports in the 1st line :

CIRCUIT BREAKER TRIPPED

BLOWING VALVE NOT OPENED
OVERCURRENT BLOWING VALVES
IMPULSE TROUBLE HORIZONTAL
IMPULSE TROUBLE VERTICAL
TROUBLE MAIN PRESSURE
BLOWING VALVE NOT CLOSED
TROUBLE FREQUENCY CONVERTER HORIZONTAL
TROUBLE FREQUENCY CONVERTER VERTICAL
LANCE LOCAL 1 INSTANTLY OFF IS ACTUATED
LANCE LOCAL 2 INSTANTLY OFF IS ACTUATED
LANCE LOCAL 3 INSTANTLY OFF IS ACTUATED
LANCE LOCAL 4 INSTANTLY OFF IS ACTUATED
PUMP ON & BLOWING VALVE NOT OPEN IN TIME

Trouble reports in the 2nd line :

LIMIT SWITCH TROUBLE SUCTION VALVE

THERMO SWITCH TROUBLE SUCTION VALVE
OVERCURRENT SUCTION VALVE
OPERATIONS TIME TROUBLE SUCTION VALVE
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LIMIT SWITCH TROUBLE DISCHARGE VALVE
THERMO SWITCH TROUBLE DISCHARGE VALVE
OVERCURRENT DISCHARGE VALVE
OPERATIONS TIME TROUBLE DISCHARGE VALVE
LIMIT SWITCH TROUBLE BYPASS VALVE
THERMO SWITCH TROUBLE BYPASS VALVE
OVERCURRENT BYPASS VALVE
OPERATIONS TIME TROUBLE BYPASS VALVE
WATER PUMP TROUBLE

In this menu it is possible to see the TROUBLE INFORMATION.

For TROUBLE RESET use F6.

The system will switched on automatically this menu whenever a trouble is active.
Also a red LED will be on, when there is a trouble active.
This menu can be switched on with the key F 3.
The trouble information will appear with a takt by one Second.

Whenever a trouble is active it will be reported.

by pressing the cursor down key an second menu line appear.

in this line the number of the waterlance that is in trouble will be shown.
REST - MENU

CLYDE BERGEMANN GMBH 46485 WESEL

-GERMANY- TELEPHONE (0) 281 815-0

This menu will be switched on automatically, whenever the system isnt in program running or manual -
local mode isnt selected and there is no trouble active after 100 minutes. 0

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