Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
R.R.Patel
Objectives
To ensure safe operation of combustion in heaters, furnaces, boilers, kilns, ovens, etc. To maintain safe operation during start up, operation & shutdown
DCS
FD FAN
Local Panel
A general purpose PLC IEC 61131 A Safety PLC QMR / TMR TUV approved
Fuel gas
P T
Components of BMS
Local control panel
Ignition push buttons , lamp indications Ignition devices Pilot and main flame detectors Solenoids operated shutdown valves with proximity switches for open & close indications Pressure, Temperature, flow transmitters BMS & ESD PLC in PIB
PILOT GAS
FUEL GAS
FUEL OIL
ESD
Standards followed
NFPA 85 Boiler & combustion Control Systems
Hazards Code API 556 Instrumentation & Controls for Fired Heaters and Steam Generators ANSI/ISA S84.01 Application of Safety Instrumented Systems for the Process Industries IEC 61508
Safety PLC
Fail safe I/O circuits with built in diagnostics CPU with built in diagnostics for memory, CPU operation, watch dog timer and all communication systems QMR /TMR architecture IEC 61508 - SIL 2 Diverse architecture to avoid common cause failure - processor, software, logic family TUV approved
Troubleshooting Guidelines
a) 1ST OUT Sequence on DCS graphics Trip signal from ESD Change of close or open indication Proximity switch failure SOV loop failure b) SOE (sequence of event) in ESD During normal heater running, Vent valve can get opened 1) by ESD signal 2) Solenoid loop failure Block valve can get closed 1) by ESD signal 2) Loss of close indication of vent valve 3) Pilot voting logic if not overridden 4) Main flame failure 5) SOV loop failure
Startup Permissive
No shutdown signal from ESD PLC All the block valves in closed & vent valves are in open condition No Pilot or Main flame is detected No valve discrepancy alarm
START PERMISSIVES 1. 2.
VENT VALVE
NO ESD SIGNAL BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN ALL PILOT & MAIN FLAMES ARE OFF NO LAMP ON LOCAL PANEL IS FLASHING
PRESSURE PRESSURE TRANSMITTER TRANSMITTER
3. 4.
TO BURNER TO BURNER
START PERMISSIVES 1. 2.
VENT VALVE
NO ESD SIGNAL BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN ALL PILOT & MAIN FLAMES ARE OFF NO LAMP ON LOCAL PANEL IS FLASHING
PRESSURE PRESSURE TRANSMITTER TRANSMITTER
3. 4.
TO BURNER TO BURNER
VENT VALVE
TO BURNER
START PERMISSIVES 1. 2.
VENT VALVE
NO ESD SIGNAL BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN ALL PILOT & MAIN FLAMES ARE OFF NO LAMP ON LOCAL PANEL IS FLASHING
PRESSURE TRANSMITTER
3. 4.
TO BURNER
VENT VALVE
TO BURNER
VENT VALVE
TO BURNER
VENT VALVE
2ND BLOCK VALVE OPENS FOR 8 SEC FOR DEPRESSURISATION > 0.3 kg/cm2
TO BURNER
Similar sequence takes place for Fuel Gas also, except that pressurisation test is done with nitrogen, hence instead of 1st block valve, nitrogen valve opens
LEAK TEST
COMPLETE
VENT VALVE
FD FAN START
PURGE START
LEAK TEST
COMPLETE
VENT VALVE
PURGE AIR FLOW > 5 furnace volume in 5 minutes DCS SENDS PURGE PERMISSIVE TO BMS PLC
TO BURNER
PURGING IN PROGREE
TO BURNER
PURGING COMPLETED
TO BURNER
PURGING COMPLETED AFTER PURGE COMPLETION, OPERATOR HAS 15 MINUTES TIME TO LIGHT UP ANY OF THE PILOTBURNERS, FAILING WHICH WILL RETURN THE SEQUENCE TO PURGE START
VENT VALVE
TO BURNER
AFTER 30 MINUTES AT LEAST (N-3) OUT OF TOTAL N PILOT BURNERS per zone SHOULD BE LIT (PILOT VOTING LOGIC)
TO BURNER
PRESS IGNITION PUSH BUTTON ONEAFTER ANOTER TO IGNITE THE PILOT BURNERS ENSURE THAT AT LEAST (N-3) BURNERS ARE LIT WITHIN 30 MINUTES TIME, N IS THE TOTAL PILOT BURNERS PER PASS
VENT VALVE
AFTER 30 MINUTES, IF COUNT OF PILOT LIT DROPS BELOW (N-3), THE PILOT GAS IS SHUTOFF AND START UP SEQUENCE IS RETURNED TO HEATER STOP CONDITION
VENT VALVE
PURGING COMPLETED AFTER PILOT BURNERS LIGHT UP, FUEL GAS (MAIN) BURNERS CAN BE LIT UP
VENT VALVE
FUEL GAS
TO BURNER
FUEL GAS
TO BURNER
VENT VALVE
FUEL GAS
FG IN
PURGING COMPLETE
AFTER PILOT BURNERS LIGHT UP, FUEL OIL (MAIN) BURNERS CAN BE LIT UP
FUEL OIL
BMS BMS +ESD PT
ESD
FUEL OIL
BMS BMS +ESD PT
ESD
FUEL OIL
BMS BMS +ESD PT
ESD
ATOMISING STEAM
FUEL OIL
BMS BMS +ESD PT
ESD
FUEL OIL
BMS BMS +ESD PT
ESD