Bharat Heavy Electricals Limited

HIGH PRESSURE BOILER PLANT, TIRUCHIRAPPALLI 620 014.

CONTROLS AND INSTRUMENTATION / FB

CI: 1608: SBC / Rev 00 PAGE 01 OF 07

WRITE UP ON SOOT BLOWER CONTROL SYSTEM

ANDHRA PRADESH POWER GENERATION CORPORATION

LIMITED

KAKATIYA THERMAL POWER PROJECT

UNIT – 2, 1X 600 MW, CUSTOMER No. 1608

Rev DATE DESCRIPTION PREPARED CHECKED APPROVED

.No.

00 06/01/2010 Initial Release

KAKATIYA SBC WRITEUP REV.00

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I) GENERAL:

Various types of Soot Blowers such as Wall Blowers, Long Retractable Blowers, and Air Heater Blowers
are envisaged for the cleaning of fireside deposits from water walls, Super Heater, Economiser, and Air
heater regions during operation of the boiler. Steam is used as blowing medium in all types of blowers.

II) BLOWERS AND VALVES COMING IN SB SYSTEM

1) Wall Blowers - 88 Nos. + 16 Nos. for future provision.

2) Long Retractable Blowers - 42 Nos. + 30 Nos. for future provision.
3) Air Heater Blowers - 2 Nos.
4) SB steam pressure control valve [SD21] (100%, pneumatic operated) - 1 No.
5) SB Main steam isolation valve [S31] with 100% capacity (motorised, with integral starter) - 1 No.
6) Aux. Steam isolation valve [SB49] (motorised, with integral starter) - 1 No.
7) SB drain temp. control valve (24VDC solenoid operated, controlled from SBC) - 5 Nos.

III) SOOT BLOWER CONTROL PANEL (SBC)

The SBCP is of Microprocessor based and built by using the Max - DNA hardware. It houses the
equipments required for auto sequential & remote manual operation of blowers and local start permit for
blowers and its valves. The blowers can be programmed in different auto sequences. Only one
sequence can be selected for operation at a time. Maximum of two blowers at a time will operate either
in auto sequence or in remote manual mode.
The blowers are programmed in different auto sequences as given below: -
i. Wall blowers - P1
ii. LR blowers - P2
iii. AH blowers - P3
iv. Wall Blower (Future provisions) - P4
v. LR Blower (Future provisions) - P5

The Mimic shows the individual SB operating status and the following General / Fault Conditions. The
mimic will be prepared as per the scheme of soot blowing with valves, fittings and instrumentation. Mimic
will be realised in HMI only.

1) AMBER LAMPS TO INDICATE

i) 110 V AC control supply at SBMCC failure
ii) LR Blower over run
iii) LR Blower mechanical jamming (left)
iv) LR Blower mechanical jamming (right)
v) LEFT LRB steam flow low (HCB 20 CF201)
vi) RIGHT LRB steam flow low (HCB30 CF201)
vii) LEFT LRB motor overloaded
viii) RIGHT LRB motor overloaded
ix) WALL Blower over run
x) WB Right/Rear steam flow low (HCB50 CF201)
xi) WB Left/Front steam flow low (HCB40 CF201)
xii) WB Right/Rear motor overloaded
xiii) WB Left/Front motor overloaded
xiv) AH Blower over run.
xv) AHB motor overloaded (RAPH-A)
xvi) AHB motor overloaded (RAPH-B)
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xvii) Boiler Trip

xviii) SB Steam Pressure Low (HCB10 CP101, CP102, CP201)
xix) Auto Sequence Interrupted
xx) SB steam isolating valve overloaded (S 31)
xxi) Aux. steam isolating valve overloaded (SB49)

2) GREEN LAMPS TO INDICATE

i) AHB Steam PR. OK (RAPH-A) ( HCB60 CP201)
ii) AHB Steam PR. OK (RAPH-B) ( HCB70 CP201)
iii) SB main steam isolating valve (S31) Closed
iv) Aux. steam isolating valve (SB49) Closed
v) AHCV (RAPH-A) (SB51) Closed
vi) AHCV (RAPH-B) (SB59) Closed
vii) SB Drain valve (SB17) Closed
viii) SB Drain valve (SB26) Closed
ix) SB Drain valve (SB35) Closed
x) SB Drain valve (SB44) Closed
xi) SB Drain valve (SB56) Closed

3) RED LAMPS TO INDICATE

i) Auto sequence ON
ii) SB main steam isolating valve (S31) Opened
iii) Aux. steam isolating valve (SB49) Opened
iv) AHCV (RAPH-A) (SB51) Opened
v) AHCV (RAPH-B) (SB59) Opened
vi) SB Drain valve (SB17) Opened
vii) SB Drain valve (SB26) Opened
viii) SB Drain valve (SB35) Opened
ix) SB Drain valve (SB44) Opened
x) SB Drain valve (SB56) Opened

4) YELLOW LAMPS TO INDICATE

i) Auto sequence completed
ii) Local start permit
iii) All Blower at Home position
iv) Left /Front - Blower Forwarding
v) Left / Front - Blower Reversing
vi) Left / Front - Blower Rotating
vii) Right / Rear - Blower Forwarding
viii) Right / Rear - Blower Reversing
ix) Right / Rear - Blower Rotating

IV) SOOT BLOWER CONTROL SYSTEM IS HAVING THE FACILITIES FOR THE FOLLOWING
FUNCTIONS: - (Realised as Soft Buttons in HMI )

1) LOCAL / REMOTE SELECTION

“REMOTE” mode is selected for operating blowers in auto sequence or manually from HMI.
‘LOCAL’ mode is selected to issue a local start permit to SBMCC for operating blowers locally .
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2) SEQUENCE SELECT (P1 to P5)

Blowers can be programmed in different auto sequences. An auto sequence can be selected by
pressing the required sequence button (P1 to P5). Only one auto sequence can be selected at a
time. Auto sequence can be reset by pressing the selected sequence button and RESET button.

3) START SEQ:-
To start the auto sequence “START SEQ” button has to be pressed along with selected sequence
Button.

4) STOP/RETRACT
STOP/RETRACT button when pressed will issue a command to stop the auto sequence and the
operating blower will be retracted back to home position.

5) RESET
After removing the fault condition, the RESET button will be pressed to reset the fault. To reset a
selected sequence RESET button has to be pressed along with the selected sequence button.

6) MANUAL START
Any blower can be started manually from HMI by selecting the blower and giving a MANUAL START
command provided the required permissives are available.

7) DISABLE/ ENABLE
Any blower can be disabled / enabled by selecting the blower and pressing the DISABLE/ ENABLE
button. Once disabled the particular blower will not be available for operation.

8) SEQUENCE CHECK
When pressed along with a sequence button will display all the blowers programmed in that
sequence on MIMIC.
9) AUXILIARY CONTROL
Soot blowing steam isolating valve and pressure reducing valves are also operated from HMI.

V) SOOT BLOWER START PERMISSIVES

1) SB isolation valve status {(S31 opened and SD21 not closed) or (SB49 open)}
2) All blowers in home position.
3) Blower motor not overloaded.
4) No Fault in system.
5) SB steam pressure adequate.
6) LR Blower jamming signal not available (Applicable for LR Blower only).
7) SB in REMOTE mode.

VI) SEQUENTIAL OPERATION

1) Switch on Panel Power Supply.

2) Put Local / Remote selector in Remote mode.
3) Select the required auto sequence.
4) Ensure start permissive Conditions
5) After attaining the required drain temperature & adequate steam pressure, to start the sequence
press START SEQ button along with selected SEQ button. The first blower will start as per selected
programme and the sequence will continue. Blower operating indication will be available on Mimic
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.The selected SEQ will automatically get reset after operation of the last blower in the sequence and
the “SEQUENCE COMPLETED” indication will become on.
6) At any point of time the selected sequence can be reset by pressing RESET button along with
selected SEQ button.
7) During the sequence operation if any fault occurs, the sequence will stop at that step and the
operating blower will be commanded to retract back to home position for faults ii to viii. After
resetting the fault, the sequence can be continued for the remaining blowers by pressing SEQ
START button along with selected SEQ button. However for fault (i) blower can not be retracted.
Hence suitable annunciation shall be made to operator for intervention and manually retracting
blower back from field. Similarly for other faults also if blower is not retracting based on command,
annunciation has to be made for operator intervention.

Fault conditions are listed below: -

i) 110V AC control supply at SBMCC failure
ii) Blower over run
iii) LR Blower mechanical jamming
iv) Blower steam flow low
v) Blower motor overloaded
vi) Boiler Trip
vii) SB Steam Pressure Low
viii) Auto Sequence Interrupted

VII) MANUAL OPERATION FROM PANEL

1) Ensure the following conditions before Manual start of any Blower.
i) Any one of the SB.isolation valve (S31, SB49) shall be opened.
ii) All blowers in home position.
iii) No Fault in system.
iv) Any Auto sequence not selected.
2) Put Local / Remote selector in Remote mode.
3) Select the blower to be operated and press manual start Button.
The start command will be issued to the selected blower. Blower operating indication will be
available on Mimic.

VIII) LOCAL START PERMIT FOR BLOWERS

1) Put Local / Remote selector in LOCAL mode.

2) Local start permit will be available if the following conditions are satisfied.
a) Any one of the SB. steam isolation valve (S31, SB49) shall be opened.
b) All blowers in home position.
c) No Fault in system.
3) The operator at field can operate any one blower by using Local Start / Retract Push Button Box.

SB steam isolation valve: -

1) For normal operation of soot blowers main steam isolation valve S31 (integral starter) shall be
opened from SBCP. Isolation valves shall be closed automatically when the control valve is opened
less than 2% and vice versa.
2) During start-up of boiler, main steam will not be available and auxiliary steam valve (SB49) shall be
opened for single/pair operation of AH blowers.
3) At a time one of the isolation valves (S31, SB49) shall be opened.
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4) SB pressure reducing valves SD21 (100% capacity) is controlled from SBC. Open /close provisions
along with status indication will be provided in the SBC HMI.

SB drain valve:-
1) SB drain valves are controlled from SBCP as shown in drawing (Scheme of soot blower piping with
valves, fittings and instrumentation). Open/ close provisions and status indications will be available
in SBCP.

IX) SBMCC

The Soot Blower Motor Control Centre consists of power supply ON/OFF Switches for incoming and
individual blower/valve motors and Ammeter (A) and Voltmeter (V) with selector switch for incomer.
Each feeder is equipped with Fuses, Power Contactors for blower Forward/Reverse and Rotary
Operation, thermal O/L Relays, aux. Contactors etc.

X) CHECKS BEFORE STARTING SB OPERATION

1) Put ‘ON' 415V, 3 Ph, AC Incoming Power Supply Switch and control supply transformer switch in
SBMCC.
2) Put ‘ON' Individual blower/ Valve feeder Power & Control Supply Switch in SBMCC.

XI) BLOWER OPERATION

1) WALL BLOWER: -
As soon as the start impulse is given, the traverse motor of Wall blower gets supply and the blower
moves forward. The red lamp in mimic glows to indicate the operation of that blower. The yellow
lamp for indication of ‘Blower Forward’ also glows. When the blower reaches its forward end position
the traverse motor trips and the rotary motor gets supply and rotates the lance. The yellow lamp for
‘Blower rotating’ glows. Simultaneously steam valve will open and allows the steam for blowing.
When the lance completes one rotation the rotary motor trips, traverse motor gets supply and the
blower retracts. The yellow lamp glows to indicate ‘Blower Reversing'. When the blower reaches
home position the mimic lamp goes off. Now the next blower in the sequence gets the pulse and
start operating.

2) LONG RETRACTABLE BLOWER

When the Long Retractable blower gets the pulse, first the rotary motor starts rotating. The ‘NO'
contact of contactor ‘CRO' for rotary motor closes and the traverse motor starts and holds through
limit switch LS-2 contact. The blower moves forward. The Red lamp in mimic glows to indicate
blower operation. Yellow indication lamps for ‘Blower Forward' & ‘Blower rotating’ glows. When the
blower reaches the forward end position, it actuates Limit switch LS-1 which stops forward motion of
the blower. Immediately the blower reverses. The yellow lamp for ‘Blower Retracting' glows. As soon
as it comes back to home position, both traverse and rotary motors are stopped and lamps in mimic
go off.

3) AIR HEATER BLOWER

When the AHB starter receives an impulse to start, the motor starts rotating & the lance starts
sweeping. Start impulse from SBC shall be ‘ON’ for 5 minutes continuously to enable limit switch LS-
1 to make and hold the power supply across the power contactor. Simultaneously the solenoid
operated control valve is opened and steam flows. When the lance moves from the initial position,
the limit switch LS-1 reset and holds supply to the starter. The OFF-DELAY timer contact holds the
supply across limit switch LS-1, when operated under manual mode from local, until it resets during
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start-up. The Red lamp in mimic glows to indicate blower operation. When the lance reaches the
forward end position the limit switch LS-2 trips and the solenoid control valve is closed. The motor
runs in the same direction and by the link arrangement the lance comes back to the initial position.
During the reverse sweep there is no soot blowing. When lance reaches initial position LS -1 trips,
motor stops rotating, and the mimic lamp goes off.

XII) NOTE:-
1) At a time, two blowers can be operated in sequence.
2) CRT/Key Boards are common for FSSS, SBC & SADC System.
3) SB operation can be made through CRT/Key Board.
4) One potential free contact output for “Any soot blower ON” to be made available from SBC for use in
BHELSONIC system.

XIII) Reference drawing numbers

1) Scope and cabling of soot blower control system – 3-96-185-11327
2) Scheme of soot blower piping with valves, fittings and instrumentation – 0-00-047-47942
3) Soot blower MCC single line diagram and feeder wiring diagrams – 3-96-186-11805 to 11816