SRI GIRIJA FERRO ALLOYS & MINERALS LTD.

, 2X36MW POWER DIVISION

SITE: OEG INDIA LTD

DCS INTERLOCK SCHEMES

BOILER-1 & 2
1. ID Fans (A,B):

Fans will be stopped if the below conditions satisfied

Trip Interlock (Protection Stop):

 ID Trip.
 ID Failed to start.
 Motor Winding temperatures High High i.e >140Deg C with 5sec Delay
 Motor & Fan Bearing temperatures High High i.e > 95Deg C with 5sec Delay
 Scoop oil I/L temp High High i.e > 100Deg C with 5sec Delay
 Scoop oil O/L temp High High i.e > 100Deg C with 5sec Delay
 Any one Scoop Lube oil pressure <0.6 Kg/Cm 2. During fan startup this interlock
will come into action after 15Secs Of fan startup.
 Fluid coupling oil tank level low switch acts.
 Furnace pressure Low Low i.e < -150mmwc 2 out of 3 selection from Furnace
pressure transmitters with 2secs delay.
 Any one ESP Hopper level high from 5fields.
 ESP I/L temp high i.e >200Deg C for a period of 30 minutes.
 ACW Pressure Low i.e <2Kg/Cm2 with 10sec delay.
 ID Fan & Motor vibration high i.e >11.2mm/sec with 5sec delay.
 Emergency pressed

For starting the Fan (Start Permissive) following interlocks to be satisfied.

 ID RTS (Ready to start) from MCC Healthy
 ID Remote Selected.
 Regulating Damper close condition.
 ID fan Fluid coupling scoop tube close condition.
 ID Fan O/L isolation damper close condition.
 ID Fan Suction isolation damper close condition.
 ID Fluid coupling oil tank level low switch normal.
 Any one ACW pump running.

2. PA Fans (A, B):

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 Fans will be stopped if the below conditions satisfied

Trip Interlock (Protection Stop):

 PA Trip.
 PA Failed to start
 Motor Winding temperatures High High i.e >140Deg C with 5sec Delay
 Motor & Fan Bearing temperatures High High i.e > 95Deg C with 5sec Delay
 Scoop oil I/L temp High High i.e > 100Deg C with 5sec Delay
 Scoop oil O/L temp High High i.e > 100Deg C with 5sec Delay
 Any one Scoop Lube oil pressure <0.6 Kg/Cm 2. During fan startup this interlock
will come into action after 15Secs Of fan startup.
 Fluid coupling oil tank level low switch acts.
 ID Fan not running condition. During Boiler startup this condition will be satisfied
after 7minutes of any ID running condition.
 Drum Level LL i.e <16.7% 2 out of 3 selection.
 PA air presure at APH O/L High High i.e >1800mmwc, 2 out of 3 from
3transmitters.
 Furnace Pressure High High i.e >150mmWC, 2 out of 3 selection from Furnace
Pressure Transmitters with 2sec delay.
 ACW Pressure Low i.e <2Kg/Cm2 with 10sec delay.
 PA Fan & Motor vibration high i.e >11.2mm/sec with 5sec delay.
 Emergency pressed

For starting the Fan (Start Permissive) following interlocks to be satisfied.

 PA RTS (Ready to start) from MCC Healthy

 PA Remote Selected.
 Regulating Damper close condition.
 PA fan Fluid coupling scoop tube close condition.
 PA Fan O/L isolation damper close condition.
 PA Fan Suction isolation damper close condition.
 PA Fluid coupling oil tank level low switch normal.
 Any one ACW pump running.
 Fluid Coupling Oil pressure OK i.e >0.6Kg/cm2 (During fan startup this interlock
will come into action after 15Secs Of fan startup)
&
Wind box steam purging completed or Bed Temp <200 Deg C (2 oo 3 from Bed
Temperature Transmitters A,B,C or 2 oo 3 from Bed temp Transmitters D,E,F) or
MS Pres <5Kg/Cm2.
3. SA Fans (A,B):

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 Fans will be stopped if the below conditions satisfied

Trip Interlock (Protection Stop):

 SA Trip.
 SA Failed to start
 Motor Winding temperatures High High i.e >140Deg C with 5sec Delay
 Motor & Fan Bearing temperatures High High i.e > 95Deg C with 5sec Delay
 Scoop oil I/L temp High High i.e > 100Deg C with 5sec Delay
 Scoop oil O/L temp High High i.e > 100Deg C with 5sec Delay
 Any one Scoop Lube oil pressure <0.6 Kg/Cm 2. During fan startup this interlock
will come into action after 15Secs Of fan startup.
 Fluid coupling oil tank level low switch acts.
 PA Fan not running. During Boiler startup this condition will be satisfied after
3minutes of PA running condition.
 Drum Level LL i.e <16.7% 2 out of 3 selection.
 SA air presure at APH O/L High High i.e >1500mmwc, 2 out of 3 from
3transmitters.
 Furnace Pressure High High i.e >150mmWC, 2 out of 3 selection from Furnace
Pressure Transmitters with 2sec delay.
 ACW Pressure Low i.e <2Kg/Cm2 with 10sec delay.
 SA Fan & Motor vibration high i.e >11.2mm/sec with 5sec delay.
 Emergency pressed

For starting the Fan (Start Permissive) following interlocks to be satisfied.

 SA RTS (Ready to start) from MCC Healthy
 SA Remote Selected.
 Regulating Damper close condition.
 SA fan Fluid coupling scoop tube close condition.
 SA Fan O/L isolation damper close condition.
 SA Fan Suction isolation damper close condition.
 SA Fluid coupling oil tank level low switch normal.
 Any one ACW pump running.
 Fluid Coupling Oil pressure OK i.e >0.6Kg/cm2 (During fan startup this interlock
will come into action after 15Secs Of fan startup) & Purge Completed.

4. Boiler Feed pumps (1,2):

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 BFP’s will be stopped if the below conditions satisfied

Trip Interlock (Protection Stop):

 BFP Trip.
 BFP Failed to start
 Motor Winding temperatures High High i.e >140Deg C with 5sec Delay
 Motor & Pump Bearing temperatures High High i.e > 95Deg C with 5sec Delay
 Scoop oil I/L temp High High i.e > 100Deg C with 5sec Delay
 Scoop oil O/L temp High High i.e > 100Deg C with 5sec Delay
 Any one Scoop Lube oil pressure <0.6 Kg/Cm 2. During fan startup this interlock
will come into action after 15Secs Of fan startup.
 Fluid coupling oil tank level low switch acts.
 Deaerator Level Low Low i.e <28%.
 Pump Suction Differential pressure high high i.e >1900mmWC.
 ACW Pressure Low i.e <2Kg/Cm2 with 10sec delay.
 Boiler Feed Pump & Motor vibration high i.e >11.2mm/sec with 5sec delay.
 Emergency pressed

For starting the Pump (Start Permissive) following interlocks to be satisfied.

 BFP RTS (Ready to start) from MCC Healthy
 BFP Remote Selected.
 BFP Suction Isolation open condition.
 BFP Fluid coupling scoop position feedback >35%.
 Fluid Coupling Oil pressure OK i.e >0.6Kg/cm2 (During fan startup this interlock
will come into action after 15Secs Of fan startup).
 SA Fluid coupling oil tank level low switch normal.
 Any one ACW pump running.

For starting the Feed pump in Auto mode following conditions to be satisfied in
addition to the above interlock.

 Feed pump selected in Remote mode.

 Feed pump selected in Auto mode.
 BFP common discharge pressure <80Kg/Cm 2 or Any one Running Feed pump
stop condition & Steam Drum Pressure >95Kg/Cm2 & BFP Discharge Isolation
valve Open Condition.

5. HP Dosing Pumps-1,2 and Agitator:

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 HP Dosing pumps & Agitator will be stopped if the below conditions satisfied

 Over current trip.

 RTS (Ready to start) from MCC not Healthy.
 Dosing Tank Level Low Low.

6. LP Dosing Pumps-1,2 and Agitator:

LP Dosing pumps & Agitator will be stopped if the below conditions satisfied

 Over current trip.

 RTS (Ready to start) from MCC not Healthy.
 Dosing Tank Level Low Low.

7. Coal Feeders (DCF-1,2):

Coal Feeders will be stopped if the below conditions satisfied

Trip Interlock (Protection Stop):

 DCF Trip
 DCF Failed to start
 Bed Temp High High i.e >990Deg C (2 oo 3 from Bed Temperatures A,B,C) or (2
oo 3 from Bed Temperatures D,E,F.)
 U Beam Temp High High i.e >980Deg C (4 oo 8 from TT-503A to TT-510A) or (4
oo 8 from TT-503B to TT-510BA)
 Both ID Fan Stop condition.
 Both PA Fan Stop condition.
 Both SA Stop condition.
 Drum Level Low Low i.e <16.7% 2 out of 3 selection.
 Seal Air to DCF Low Low Switch acts.
 Spreader Air to DCF Low Low Switch acts.
 Discharge chute KGV Close condition.

For starting the DCF (Start Permissive) following interlocks to be satisfied.

 DCF RTS (Ready to start) from MCC Healthy.
 DCF Remote Selected.
 DCF Enable start interlock ok i.e Bed Temp normal, U Beam Temp normal, Any
ID, PA, SA running condition, Drum level normal, Seal Air to DCF Low Low Switch
normal, Spreader Air to DCF Low Low Switch normal, Discharge chute KGV Open
condition.

8. Lime Stone RAV (1,2):

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 Rotary Feeders will be stopped if the below conditions satisfied

 Over Load trip.

 Respective DCF Stop.

9. MDC RAV:
 Over Load trip.
 No One DCF is running.

10. Oil pump motors:

Oil pump motors will be stopped if the below conditions satisfied

 Over Load trip.

 Oil Tank Level Low Low.

11. Burner Management System:

i. Pre Interlocks satisfied
1. ID, PA, SA running condition,
2. Furnace pressure OK (Not High High (>150mmWC), Not Low Low
(<150mmWC).
3. DCS emergency not pressed,
4. Drum level Ok (Not High High(>80%), Not Low Low(<16.7%))
5. PA Air flow >14% of rated i.e >18.2TPH.
6. SA Air flow to burner >25TPH i.e 50% of Burner air flow.
7. Startup Bed temp < 760Deg C.

ii. Purge Ready to start:

1. Pre interlock satisfied,
2. No flame in furnace,
3. All oil and block valve close condition.

iii. Purge in progress:

1. Burner-A Air sleeve damper A open (Combustion air Damper).
2. Burner-B Air Sleeve damper B open (Combustion air Damper).

Total Purge time is 5minutes.

iv. Main Interlock OK:

1. Pre interlock Satisfied,
2. Purge Finished.

v. Oil Burner A or B ready to start:

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 1. Oil pressure not low i.e <2.5Kg/Cm2.
2. Main Interlocks satisfied.
3. Oil gun retracted position.
4. Block valves close condition.
5. MFT valve open condition.
6. Igniter sparking not over.
7. Pilot Gas pressure not <0.07Kg/Cm2.
8. Atomizing air pressure not <3Kg/cm2.
9. Furnace flame not there.

12. Boiler Emergency Vent valve (SOV_701):

Valve Opening Permissive in Auto Mode:
1. Valve in Auto selection.
2. Steam flow <16TPH and if startup vent valve open command <20% and if U-
Beam temp >485Deg C valve will open.
3. Both PA fan off condition & U Beam temp >485Deg C valve will open.

13. Electromatic Safety Valve at SSH O/L (EMRV):

Protection Open:
If Boiler Outlet pressure > 109Kg/cm2 valve will be opened irrespective of Auto or
Manual mode.
Protection Close:
If Boiler Outlet pressure < 107Kg/cm2 valve will be closed irrespective of Auto or
Manual mode.

14. ID Damper Logic:

Protection Open: If Both ID stops all Dampers open for a period of 5minutes. After
5minutes permission will come for closing the Dampers for starting the Fans.
If anyone Fan started permission will come for closing the other Fan dampers.
Damper Mode: If Damper mode selected scoop will go to 100% (Protection UP will act on
scoop positioner).
VSFC Mode: If Scoop mode selected and if the Fan Started, Dampers will fully open with
30secs delay.

15. PA Damper Logic:

Protection Open: If Both PA stops all Dampers open. If anyone Fan started permission will
come for closing the other Fan dampers.
Damper Mode: If Damper mode selected scoop will go to 100% (Protection UP will act on
scoop positioner).
VSFC Mode: If Scoop mode selected and if the Fan Started, Dampers will fully open with
30secs delay.
16. SA Damper Logic:

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 Protection Open: If Both SA stops all Dampers open. If anyone Fan started permission will
come for closing the other Fan dampers.
Damper Mode: If Damper mode selected scoop will go to 100% (Protection UP will act on
scoop positioner).
VSFC Mode: If Scoop mode selected and if the Fan Started, Dampers will fully open with
30secs delay.

17. Furnace DP Transmitters Impulse line purging Shut-off valve(SOV303) Logic:

Protection Open: If any PA ON condition.
Protection Close: If both PA OFF condition.

18. Wind box Steam Purging Logic:

Steam purging MOV Auto Open: Wind box pres <1800mmWC with 10sec delay and if No
SA, PA, ID running for 10min and if Bed Temp >200Deg C Auto open command will be
generated and MOV will be opened for a period of 5minutes (Steam Purge time).
This cycle will be repeated until Boiler Starts or Bed Temp <200Deg C.

19. Wind box Damper (FY303 & FY304) Logic:

Protection Close: Protection close will act if the following conditions satisfy
1. If Both PA stop condition
2. PA air pres after APH <1200mmWC and both wind box dampers open command >10%.
Enable Open: Dampers open permission will come if the following conditions satisfy.
1. PA air pres after APH >1200mmWC
2. Both Wind box dampers >10% command given.

20. Wind box to APH Damper(SOV-351).

Protection close: Both wind box dampers command above 10% and PA ON protection
close will act.
Protection open: Both PA OFF protection open will act with 3sec delay.

21. Damper (SOV-352).

Protection close: Both PA OFF protection Close will act with 3sec delay.
Protection open: Both PA ON protection open will act.

22. PA Fan Air to Prim APH Damper Actuator:

Protection open: Both PA fan off protection up (100% Open) will act. If any PA on
protection up will reset and give permission to operate the damper.

23. PA Fan Air to Prim APH Byp-Damper Actuator:

Protection close: Both PA fan off protection down (Full close) will act. If any PA on
protection down will reset and give permission to operate the damper.

24. SA Fan Air to Sec APH Damper Actuator:

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 Protection close: Both PA fan off protection down (Full close) will act. If any PA on
protection down will reset and give permission to operate the damper.

25. SA Fan Air to Sec APH Byp-Damper Actuator:

Protection close: Both PA fan off protection down (Full close) will act. If any PA on
protection down will reset and give permission to operate the damper.

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