. O N G IN W A R D
RP0
6 1 1 N K 9 9 1 5 N
Revised according to owner comment after software FAT in KM. (28 Jan. 2005) KS 1
Y. Ono
Y.Ono
(DNV)
A4
94
A3
0
TOTAL 95 SHEETS WITH COVER
DAEWOO H.NO.2227 / 2228 / 2235 T. Yuki
MAIN BOILER(MB-4E-NS2)
Y. Ono K. Saito
Functional Design Specification for Boiler Control DRAWING NO.
K1A32/38/44
61500 G377
N51-99K-N116
MITSUBISHI HEAVY INDUSTRIES, LTD. NAGASAKI SHIPYARD & MACHINERY WORKS DRAWN 25Nov.2004 ISSUED
1
Kongsberg Functional Design Document (KFDD) Boiler Control System DSME 2227/2228/2235
Project:
7069
Product Synopsis:
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
Document number:
1001854
Revision:
Customerdocnumber:
Documentversion:
Contract number:
Rev.
Date
0D
Number of pages:
Reason for issue
Made by
0.4 93
Checked
A
28.04.2004
Forinternalcomments
BA
B
13.05.2004
For Approval
OHJ
HAE
C
15.07.2004
Reissueforapproval
SN
MS
EW
D
26.01.2005
Reissueforapproval
OHJ
GM
OSL
E
Kongsberg Maritime AS
HAE
Approved HAE HAE
Kongsberg Maritime AS
History Revision
Description of Change
A
For internal comments
B
For Approval
C
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 SEQUENCE S........................................................................................15
4.1
Fuel Oil Burning..................................................................................................16
4.2
Gas burning .........................................................................................................24
4.3
Burner Auto Mode...............................................................................................29
4.4 4.5
Burner Automatic Increase/Decrease ..................................................................30 Fuel Mode Changeover .......................................................................................34
4.6
Fuel Oil Boost UP ...............................................................................................42
4.7
5
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
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
1001854 / 0D / Page 3 of 93
Kongsberg Maritime AS
5.10
Hot Start Valve ....................................................................................................67
5.11
Viscometer Outlet Valve .....................................................................................68
5.12
Fuel/Atomizing Valve Abnormal ........................................................................69
5.13
Output to Main Turbine.......................................................................................70
6
BOILER TRIP .......................................................................................................71
7
BOILER OPERATION PANELS ........................................................................78
7.1
BGB Graphic Panel .............................................................................................78
7.2
Manual Loader Functions....................................................................................82
7.3
8
Emergency Operation ..........................................................................................84 7.3.1
No.1 or No.2 part........................................................................................ 84
7.3.2
Common Part.............................................................................................. 85
SOOT BLOWING SEQUENCES ........................................................................85
8.1
Long Soot Blower Sequence ...............................................................................87
8.2
Rotary Soot Blower Sequence.............................................................................87
8.3
Boiler & Econ omizer Soot Blower Sequence .....................................................88
8.4
Economizer Soot Blower Sequence ....................................................................90
9
ATTACHMENTS ..................................................................................................93
1001854 / 0D / Page 4 of 93
Kongsberg Maritime AS
1 GENERAL ITEMS 1.1 Definitions/Abbreviations Local control
Operation of the equipment is outside the IAS system (Switchboard or local panels).
Remote control
Operation of the equipment is performed from the IAS system.
Manual control
Operation of the equipment is performed manually by the operator from the IAS operator stations or BGB.
Automatic control
Operation of the equipment is performed by IAS control logic (remote mode only).
ABC
Automatic Boiler Control
AVR
Automatic Voltage Regulation
BGB BNP
Boiler Gauge Board Burner Operation Panel
CCR
Cargo Control Room
CTR
Custody Transfer System
DG
Dieselgenerator
DP
Differential Pressure
E/R
Engineroom
ECR
Engine Control Room
EOP
Emergency Operator Panel
EOT
Engine Order Telegraph
ESD
Emergency Shutdown
F&G
FireandGas
FDF
ForcedDraftFan
FDS
Functional Design Specification
FO
Fueloil
FS
Field Station (Cabinet with controller and/or RIO modules)
1001854 / 0D / Page 5 of 93
Kongsberg Maritime AS
FV
ForcingVaporizer
FW
Freshwater
GMS
Gas Management System
HD
High Duty Compressor
HS HT
HandSwitch HighTemperature
HV
High voltage (6.6 kV systems)
I/O
Input/output
IAS
Integrated Automation System
IGC code
International Code for the Construction and Equipment of Ships carrying Liquefied Gases in Bulk.
IGV
InletGuideVane
KM
KongsbergMaritime
LD
LowDutyCompressor
LNG
Liquefied Natural Gas
LO
Lubricationoil
LR
LloydsRegister
LT
Lowtemperature
LV
Low Voltage (440V / 220 V systems)
MCC
Motor Control Center
MCR
Maximum Continuous Rate
MHI
Mitsubishi Heavy Industries
MLP
Manual Loader Panel
MV
MainVaporizer
MT
MainTurbine
NDU
Net Distribution Unit
OS
OperatorStation
PMS
Power Management System
PV
ProcessVariable
RCS
Remote Control System
RCU
Remote Controller Unit
1001854 / 0D / Page 6 of 93
Kongsberg Maritime AS
RIO
Remote Input Output Unit
SBRP
Soot Blower Relay Panel
SP
SetPoint
SVC
Simrad Vessel Control
SW TG
Seawater TurbineGenerator
VDU
Video Display Unit
1001854 / 0D / Page 7 of 93
Kongsberg Maritime AS
1.2 Flowchart symbols Symbols Condition for next step Accomplished OR Failed (Timout)
Description Action Failed (Timout)
This symbol represents any kind of processing function.
Accomplished
This symbol represents a decision or switching type function
This symbol represents a named process, such as a subroutine.
This symbol represents data input by manual means
This symbol represents a process performed by operator or automatically by process event.
Indicates a crossreference within the same page of the flow chart.
This symbol represents the end of a program flow.
This symbol represents a data that is displayed for human use.
This symbol represents a delay/timer
1001854 / 0D / Page 8 of 93
Kongsberg Maritime AS
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:
MitsubishiHeavyIndustries.
Type:
MB-4E-NS2.
Steampressure:
60.3bar.
Steamtemperature:
515
Evaporation:
C.
°
Normal:50,000kg/h,max:61,500kg/h
Feed water temperature at ECO outlet:
139,8 °C.
EfficiencyFuelOil:
88,5%
Boilerdesignpressure:
76,5bar
Auxiliary de super heater outlet: Steam quantity: Temperature:
Max: 40,000 kg/h Max:350 °C , normal: 288.5 °C.
1001854 / 0D / Page 9 of 93
Kongsberg Maritime AS
Figure showing general arrangement: IAS Ethernet HUB A
IAS Ethernet HUB B
MB2 Control Cabinet
MB1 Control Cabinet
Boiler Common / Soot blowers Cabinet
RCU
RCU
RCU
RCU
RCU
RCU
HUB
HUB
HUB
HUB
HUB
HUB
RIO
Analogue control sensors
RIO
Analogue control sensors
RIO
Common AI/AO
RIO
Flame scanner #1 MT Trip/Pwr Reduction
RIO
Flame scanner #1 MT Trip/Pwr Reduction
RIO
Common DI/DO
RIO
Flame scanner #2
RIO
Flame scanner #2
RIO
Common DI/DO
RIO
Analogue Control Se nsors
RIO
Analogue Control Sen sors
RIO
Analogue Control Sensors
Analogue Control Vlv' s
RIO
Analogue Control Vl v's
Analogue Control Vlv's
Manual Loader
RIO
Manual Loader
RIO
Manual Loader
RIO
Manual Loader Operator Panel
RIO
Manual Loader Operator Panel
RIO
Div control
RIO
Common Vlv's Operator Panel Others
RIO
Common Vlv's Operator Panel Others RIO
Soot Blower Control
RIO
Common Vlv's Operator Panel
RIO
Common Vlv's Operator Panel RIO
Soot Blower Control
RIO
Operator Panel
RIO
Operator Panel RIO
Soot Blower Control
RIO
No1 Burner Control
RIO
No1 Burner Control RIO
Soot Blower Control
RIO
No2 Burner Control
RIO
No2 Burner Control
RIO
No3 Burner Control
RIO
No3 Burner Control
SBP
BGB
1001854 / 0D / Page 10 of 93
Kongsberg Maritime AS
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 isloader locatedfunctions at the BGB. It contains lamps and switches for local boiler control also manual 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
1001854 / 0D / Page 11 of 93
Kongsberg Maritime AS
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.
1001854 / 0D / Page 12 of 93
Kongsberg Maritime AS
3.2 Burner Management Burner sequence control and boiler control loops are integrated in the ABC process stations. Data exchange between the process stations is done via the dual Ethernet.
All commands and parameters are available from IAS/ABC operator stations. In addition commands and control can be made from the Boiler Gauge Board, via local/remote switches.
Emergency operation of burner can be done from the EOP, which is totally independent from IAS. When emergency operation is selected, both ABC and BMS are changed to emergency mode.
Boiler shutdown system is mostly within the IAS boiler control system. Some shutdowns are hardwired (by MHI).
3.3 CPU Redundancy Each of the ABC process stations are equipped with a redundant CPU. Normally the main CPU runs and activates the process outputs. The slave CPU is running in parallel with the main CPU but process output are disabled (hot backup). In case of main CPU fails, the process outputs to the AO/DO cards are controlled by the slave CPU.
1001854 / 0D / Page 13 of 93
Kongsberg Maritime AS
3.4 Power Distribution Each of ABC cabinets are supplied with redundant power system. See figure below, indicating the power supply principle. Each of the UPS & AC/DC converters contains sufficient capacity to supply the system.
Process Station Cabinet Main Supply Emerg Supply
220V AC UPS 1
RCU A 24V DC 220V AC
UPS 2
RCU B 24V DC
RIO Units
BGB 220V AC 24V DC RIO Units 220V AC 24V DC
SBRP
RIO Units
1001854 / 0D / Page 14 of 93
Kongsberg Maritime AS
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.
1001854 / 0D / Page 15 of 93
Kongsberg Maritime AS
4.1 Fuel Oil Burning Starting fuel oil burners:
The individual fuel oil burners can be started and stopped either from the operator station (IAS control) or from the BGB (local control). •
If all flames are off and operation position is BGB then first burner starting must be done from BGB. Operation position transfer BGB => IAS is blocked during boiler stopped condition.
•
If all flames are off and operation position is IAS then first burner starting can be done from IAS.
In addition burners can be started and stopped from EOP (not described here since this is an independent system). •
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).
1001854 / 0D / Page 16 of 93
Kongsberg Maritime AS
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.
1001854 / 0D / Page 17 of 93
Kongsberg Maritime AS
Flowchart for starting fuel oil burners, the first FO burner: SEQ-1 Start Oil Burner (Initial FO Burner)
Note : Only One Burner Can Be Started At The Time Condition for next step
Start Start Permissive Terminate
Action
- Atm Steam Vlv Opened & - Steam Purg Vlv Closed
Open Bnr Atm Steam Valve & Close Steam Purge Valve Timeout : 10 sec
Error
- Boiler Purged Status Set
Start Furnace Purge Sequence (SEQ-2) Timeout : 6 min
Error
- Fd Fan Vane In Start Pos(2-6%)
Force Fd Fan Vane To Start Pos. (5%) Timeout : 10 sec
Error
- Selected Bnr Register Opened & - Not Selected Registers Closed
Close Bnr Register which are not set for start Timeout : 10 sec
Error
Close FO Recirc Valve Timeout : 10 sec
Error
Set FO Ctrl Vlv To Start Pos(18%) Timeout : 20 sec
Error
Check Air Rate & FO Press & FO Temp Timeout : 60 sec
Error
Check All Flames are OFF Timeout : 5 sec
Error
Open FO Valve 223B & Insert Igniter Timeout : 20 sec
Error
- FO Recirc Valve Closed
- FO Ctr Vlv In Start Pos(15-21%)
- Air Rate Normal (8000-4000kg/h) & - FO Press Ok(>10bar) & - FO Temp Ok or Temp byps On OR
- Burner On from BGB(local) if all Bnr off - Burner On from Monitor(IAS) if all Bnr off andOR IAS Mode established
- 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
- Boiler FO Shutoff Vlv Close Cmd - Boiler Trip - FO Trip OR
Waiting timer 10s
- All Flames OFF Waiting Timer: 1s
- 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
Activate Retractable Igniter if Not Portable igniter Selected Or Activate Portable Igniter if Selected
- Falme Fail Waiting Timer: 5s
- Set Alarm - Close Burner Fo Valve's
- Burner Fo Valve 1 Opened & - Burner Fo Valve 2 Opened & - Flame Detected Direct Error if:
Error
Timeout : 10 sec
Open Burner Fo Valve 225B Timeout : 10 sec
- Deactivate & Retract Igniter Error
(Flame fail is activated 7s afterFO vlv open cmd)
- Close Burner Register If Gas Burner Is Not Active - Close Atomize Steam Valves
- Igniter Deactivated & - Igniter Retracted Waiting timer 7s
Deactivate & Retract Igniter Timeout : 10 sec
Error
Release Fd Fan Vane & FO Control Valve Timeout : 5 sec
Error
- Open Stm Purge Vlv if Any Bnr is ON - Release FDF Vane
- Fd Fan Vane Released & - FO Control Valve Released Note:
FO Valve 223B is Slow Acting Downstream side FO Valve 225B is Fast Acting
End
1001854 / 0D / Page 18 of 93
- Release FO Ctr Vlv - Open FO Recirc Valve
Kongsberg Maritime AS
Flowchart for furnace purging:
SEQ-2
Start Start Permiss ive Terminate
Furnace Purging Condition for nex t step - Burner 1 Register Opened & - Burner 2 Register Opened & - Burner 3 Register Opened
- FDF in Furn Prg Pos +/- 3% & - A ir Flow > 40.000 Kg/h
- Air volume > 900 m3 & - Minimum Timer 60 sec
- Start fr om Burner Start seq. or - Manual Purge from BGB in Local mode or - Manual Purge from IAS in IAS mode
Ac tion Open All Burner Registers Timeout : 15 sec
Error - All Bnr FO Vlv's Closed & - FDF Run
Force Fd Fan Vane Fully Open Timeout : 30 sec
Error
Purging ( min 60s ) Timeout : 300 sec
Error
Set
- Purge Status > 1min Or - FDF Not RunOr - Any FO Vlv Open Command Or - FO Shut Valve Open & A ny Bnr On
Reset
Set Boiler Purged Status (No Set if Man Purge)
- FDF Stopped - Boiler Manual Trip
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.
1001854 / 0D / Page 19 of 93
Kongsberg Maritime AS
Starting fuel oil burners, when another burner is on:
In manual mode operator is responsible for checking FO pressure and boiler master demand him self. Auto mode is described in the chapter for burner automatic increase by / 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 valve’s (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.
1001854 / 0D / Page 20 of 93
Kongsberg Maritime AS
Flowchart for starting fuel oil burners, when another FO burner is on: SEQ-3
Note : Only One Burner Can Be Started At The Time Condition for next step - Atm Steam Vlv Opened & - Steam Purge Vlv Closed &
Start Start Permissive Terminate
Start Oil Burner (Next FO Burner) Action Open Atm Steam Vlv & Close Steam Purge Vlv
- 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
Timeout : 10 sec - FO Press OK OR - FO Mode OR - BMS Manual Mode
FO -Recirc Valve Closed
- FO Control Vlv in Start Pos OR - Any FO Bnr On
- 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
- Burner FO V(223B) Open Cmd & - Burner FO V(225B) Open Cmd
-Flame Detected Waiting timer 5s
Adjust FO Press if Auto & Dual Timeout : 10 sec
Close FO Recirc Vlv Timeout : 10 sec
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
Set FO Control Vlv to Start Pos if No FO Bnr On Timeout : 10 sec
Insert and activate Retractable Igniterif Not Portable igniter Selected Or Activate Portable Igniter if Selected
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
If Corresponding GAS Bnr is Off Timeout : 30 sec
Open Bnr FO Vlv (223B) & Open Bnr FO Vlv (225B) Timeout : 10 sec (Flame fail is activated 7s afterFO vlv open cmd)
Open Burner Register after 2 s Timeout : 10 sec
Error
Error
FO Burner Ignition Seq Failed
Close Burner FO Valves Deactivate & Retract Igniter
- Ignitor Deactivated & - Ignitor Retracted Waiting timer 7s
Deactivate & Retract Ignitor Timeout : 20 sec
Error
Close Burner Register If Gas Burner Is Not Active Close Atomize Steam Valve Open Steam Purge Valve
End
1001854 / 0D / Page 21 of 93
Kongsberg Maritime AS
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
Kongsberg Maritime AS
Flowchart for stopping fuel oil burners:
1001854 / 0D / Page 23 of 93
Kongsberg Maritime AS
4.2 Gas burning Start up of gas burning can be done either by manually starting each burner or by using the automatic sequence.
Operator Preparations:
The operator must prepare the following conditions before GAS firing can start: •
FO firing must be established.
•
Reset of all GAS trip conditions.
•
Open Master GAS valve.
•
Open boiler GAS valve.
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.
1001854 / 0D / Page 24 of 93
Kongsberg Maritime AS
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
- Waiting Timer 3 sec
- Burner Gas Valve 1 Opened & - Burner Gas Valve 2 Opened &
SEQ-5 Start Gas Burner
Start Start Permissive Terminate
- Gas Burner On f rom BGB (Local Mode) - Gas Burner On from Monitor(IAS) OR - Start Req from Bnr auto inc/dec s eq. (SEQ-9 step 3, SEQ-9 step 6)
Ac tion Check Gas Ctrl Vlv To Start Pos. If No Other Gas Burner Is A ctive Timeout : 10 sec
Error
Set Air Bias Timeout : 10 sec
Open Burner Gas Valves Timeout : 10 sec
Error
- Master Gas Valve Open - Boiler Gas shutoff valve Opened - Burner Gas V alve1 Closed - Burner Gas V alve2 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 V alve Closed - Not Seq Jam - Corresponding FO Bnr On
&
- Master Gas V alve Closed - Gas Trip OR
Note : If Corresponding Oil Burner "Flame On" Signal Is Lost Before Gas Flame Is Detected, The Start Sequence Will Be Terminated.
Release Gas Control Valv e
GAS Burner Ignition Seq Failed
Reset Air Bias
- Reset Air Bias A djustment
- Close Burner Gas V alves
End
1001854 / 0D / Page 25 of 93
Kongsberg Maritime AS
Flowchart for stopping fuel gas burners:
SEQ-6 Stop Gas Burner Condition for next step
Start Start Permissive
(SEQ-10 step2, SEQ-10 step4) - Stop request from Dual=>FO seq - Bnr Falme Fail
Ac tion
- Burner Gas Valve 1 Closed & - Burner Gas Valve 2 Closed
Close Burner Gas Valves Timeout : 10 sec
Error
- Air Bias Adjustment is Reset
Reset Air Bias Adjus tment Timeout : 10 sec
Error
Furn Purge Req If Last Bnr Timeout : 10 sec
Error
Start Burner N2 Purge If Any Bnr Firing Timeout : 10 sec
Error
Close Bnr Register If FO Bnr is Off & Not Furn Purge Timeout : 10 sec
Error
- Any Burner Is Active Or - Furn Purge Run
- Stop from BGB (Local Mode) - Stop from Monitor(IAS) - Stop request f rom burner inc/dec OR
- Burner Gas Valve's Not Close Cmd
Waiting Timer 10 sec
- Burner N2 Purge V Opened Or - Furn Purge Seq Run
Gas Burner Extinguish Seq Failed - Bnr register Closed Or - FO Bnr On Or - Furn Purge in Progerss
- Close Burner Gas Valves - Close Air Register if FO Burner is Not A ctive - Close Burner N2 Purge Valve
End
1001854 / 0D / Page 26 of 93
Kongsberg Maritime AS
Flowchart for Boiler Gas Valve Open: SEQ-7 Blr Gas Valve Open Condition for next step Blr Gas -Vlv Opened
Start Start Permissive Terminate
Gas - Control Vlv in Ign Pos
OR
Action Open Blr Gas Valve. Error Timeout : 10 sec - Master Gas Valve Open - All Bnr Gas Vlv's Closed - All Bnr N2 Purge Vlv's Closed - Not Boiler Trip - Not FO Trip - Not Gas Trip - Hdr N2 Purge Seq Not Active
Timer 5 sec
- Hdr N2 Vent Vlv Closed
- Open from Monitor(IAS)
Close Hdr N2 Vent Vlv Timeout: 10 sec
&
Error
Set Gas Control Vlv to Ignition Pos. Error Timeout : 10 sec
- Master Gas Valve Closed - Gas Trip OR
Boiler Gas Valve Open Seq Failed - Close Boiler Gas Valve - Open Header Vent Valve - Release Gas Control Vlv
End
1001854 / 0D / Page 27 of 93
Kongsberg Maritime AS
Flowchart for Boiler Gas Valve Close: SEQ-8 Blr Gas Valve Close Condition for next s tep
Start Start Permiss ive
- Close from Monitor(IAS) - Close if Gas Trip
Ac tion Close Blr Gas Vlv Timeout: 10 sec
- Blr Gas Vlv Closed
Error - Blr Gas Vlv Not Closed
Set Gas Ctr Vlv Fully Closed Timeout: 10 sec
- Gas Ctr Vlv Fully Closed(<1%)
Error
FO Burning On ?
No
Yes -
If FO Burning: Start Hrd/Bnr N2 Purge to Furn Error (SEQ-19) Timeout : 1 0 sec
Hrd/BnrN2PurgetoFurnSeqRun
A
Yes Start Hdr N2 Purge to Vent (SEQ-17) Timeout : 1 0 sec
- Hdr N2 Purge to Vent Run
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
1001854 / 0D / Page 28 of 93
OR
Kongsberg Maritime AS
4.3 Burner Auto Mode Burner auto mode can be selected when the burning burners are burning in the same fuel mode e.g. FO, Dual or FG. Base burner is required in order to establish auto mode. In case of burner manual mode, any burner can be operated. For example, one gas burner firing can be made at gas only mode. Burner automatic increase / decrease, fuel mode changeover sequence is cancelled during burner manual mode. When operator selects burner manual mode, operator must also take care of suitable burner number to be matched with boiler load and general boiler safety. FO Mode Bnr1 FO Burning Bnr2 FO Burning Bnr3 FO Burning
&
&
Bnr1 GAS Bnr2 GAS Burning Bnr3 GAS Burning Burning
OR
& OR
Dual Mode Bnr1 FO Burning Bnr1 GAS Burning
& & OR
Bnr2 GAS FO Burning Bnr2 Burning
&
&
OR
OR
&
OR
Auto Mo de Pos sible
& Bnr3 FO Burning Bnr3 GAS Burning
&
GAS Mode Bnr1 GAS Bnr2 GAS Burning Bnr3 GAS Burning Burning
Bnr1 FO Burning Bnr2 FO Burning Bnr3 FO Burning
&
OR
&
& OR
FO Trip Ctr Pos IAS FO Shut V Open Bnr1 Flame Fail Bnr2 Flame Fail Bnr3 Flame Fail
OR &
Bnr1 FO or Gas Burning Bnr1 Gas Burning Bnr2 Gas Burning Bnr3 Gas Burning
&
OR
&
FO Trip
1001854 / 0D / Page 29 of 93
Kongsberg Maritime AS
4.4 Burner Automatic Increase/Decrease Burner Increase:
When burner auto mode is selected, the number of burners is controlled automatically according to the boiler demand. This mode is not applicable in gas only firing of one gas burner.
The system will monitor the boiler demand e.g. output from master pressure controller and the FO pressure or total fuel calorie. Also during manoeuvring a minimum numbers of burners are considered.
The priority for starting is predefined as follows: No.1 burner => No.2 burner => No.3 burner.
The priority for stopping is predefined as follows: No.3 burner => No.2 burner => No.1 burner.
Burner Increase: Request for next burner will be calculated as follows:
Mode
FO
Dual
GAS
No Of Bnr
Limit
Result
1 bar
Boiler demand > 13,5 Gcal/h & FO pressure > 13 bar
1 => 2 bnr
2 bnr
Boiler demand > 27,0 Gcal/h & FO pressure > 12 bar
2 => 3 bnr
1 bnr
Boiler demand > 14,0 Gcal/h & total fuel calorie > 14,0 Gcal/h & FO press > 12 bar
1 => 2 bnr
2 bnr
Boiler demand > 28,5 Gcal/h & total fuel calorie > 28,5 Gcal/h & FO press > 10 bar
2 => 3 bnr
2 bnr
Boiler demand > 25,0 Gcal/h & GAS Press > 0,1 bar
GAS=>Dual
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.
1001854 / 0D / Page 30 of 93
Kongsberg Maritime AS
Burner Decrease:
Request for stopping burner will be calculated as follows: Mode
FO
Dual
GAS
No Of Bnr
Limit
Result
3 bnr
Boiler demand < 16,0 Gcal/h & FO pressure < 5,5 bar
2 bnr
Boiler demand < 8,0 Gcal/h & FO pressure < 5,0 bar & M/T stop for 15 min.
2 => 1 bnr
3 bnr
Boiler demand < 16,0 Gcal/h & total fuel calorie < 18,0 Gcal/h
3 => 2 bnr
2 bnr
Boiler demand < 9,0 Gcal/h & total fuel calorie < 10,2 Gcal/h & M/T stop for 15 min.
2 => 1 bnr
3 bnr
Boiler demand < 17 Gcal/h & GAS hdr pressure < 0,12 bar
3 => 2 bnr
2 bnr
Boiler demand < 6,0 Gcal/h & GAS hdr pressure < 0,1 bar
GAS=>Dual
3 => 2 bnr
Main Turbine Interaction:
In case of main turbine trip the numbers of burners are limited to maximum 2 burner. TimerOff
MT Vlv Lift > 50%
Crash Astern, Crash Stop (Burner No3 Auto Decrease) (By SEQ-10)
30s
&
MT Telegraph Stop OR MT Telegraph Astern MT Vlv Lift Astern Full
&
TimerOff
MT Vlv Lift Astern Full
30s
& OR MT Telegraph Stop MT Telegraph Astern
&
MT Vlv Lift > 50%
1001854 / 0D / Page 31 of 93
Crash Ahead, Crash Stop (Burner No3 Auto Decrease) (By SEQ-10)
Kongsberg Maritime AS
Flowchart for Burner Automatic Increase:
SEQ-9 Burner Increase
Condition for next step
Start Start Permissive
- FO Mode: Boiler Demand & FO Prs - Dual Mode: Boiler Demand & Tot Calorie Input OR
Terminate
- 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
Action
- Burner 2 is OFF - Burner 2 Ready*1)
Check Burner 2 is OFF: Timeout : 1sec
No 1
OR
Start FO Burner 2 (SEQ-3) if FO or Dual mode Timeout : 60sec
- FO Burner 2 is ON & - Ignition Seq Compleate
Stop FO Burner 2 (SEQ-4)
Error
7 2
Start GAS Burner 2 if: Dual Mode & GAS Bnr2 is OFF (SEQ-4) Timeout : 60sec 3
- FO Mode, OR - Burner2 is Dual Firing
Stop GAS Burner 2 (SEQ-6)
Error
8
Condition for next step
Action
- Burner 3 is OFF - Burner 3 Ready
Check Burner 3 is OFF: Timeout : 1sec
No 4
- FO Burner 3 is ON - Ignition Seq Compleate
- FO Mode, OR - Burner 3 is Dual Firing OR GAS mode
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
Stop FO Burner 3 (SEQ-4) 9
Error 6
Stop GAS Burner3 (SEQ-6) 10
Alarm: Burner Increase Failed
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
Flowchart for Burner Automatic Decrease: SEQ-10 Burner Decrease
Condition for next step
- Burner 3 is ON
- FO Burner 3 is OFF & - GAS Burner 3 is OFF
-FO Mode: Boiler Demand & FO Prs - Dual Mode: Boiler Dem & Tot Calorie OR - GAS Mode:Boiler Demand & GAS Prs - MT Chrash Ast/Ahd if 3 Bnr Firing - MT Trip & 2bnrs or More Firing
Start Start Permissive Terminate
Action Check Burner 3 is ON: Timeout : 1sec
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
- Number of burners are 2 or more 1
No
- Telegraph Stop + 15min - Auto Mode Selected - Bnr increase Seq Off - FO => Dual Seq Off - Dual => GAS Seq Off - GAS => Dual Seq Off - Dual => FO Seq Off - FO Boost Up Seq Off - Not Burner Abnrmal - Not Seq Jam
Error
&
2
Condition for next step - Burner 2 is ON
Action Check Burner 2 is ON: Timeout : 1sec
No 3
Stop FO Burner 2 if:
- FO Burner 2 is OFF& - GAS Burner 2 is OFF
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
4
Alarm: Burner Dec. Failed 5 End
1001854 / 0D / Page 33 of 93
Kongsberg Maritime AS
4.5 Fuel Mode Changeover There are three different modes of fuel selection. Fuel Oil Only:
Only oil burners ON.
Dual Fuel:
Both gas and oil burners ON
Fuel Gas Only:
Only gas burners ON
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.
1001854 / 0D / Page 34 of 93
Kongsberg Maritime AS
Flowchart for Changeover FO => Dual: Start Start Permissive Terminate
SEQ-11 Mode: FO => Dual
Condition for next step - GAS Control Vlv in Start Pos
- Air Flow Controller Add Air Set
Action Set GAS Control valve to start position Timeout : 1sec 1
Set Add Air to Air Flow Controller Timeout : 1sec
No
Error 2
- (Bnr1 GAS Bnr is ON &
Open Bnr1 GAS Valves (1&2)
- (Bnr2 GAS Bnr is ON or Bnr2 FO Bnr is OFF) &
Open Bnr2 GAS Valves (1&2) if FO Bnr On
- (Bnr3 GAS Bnr is ON or Bnr3 FO Bnr is OFF)
Open Bnr3 GAS Valves (1&2) if FO Bnr On
Error
Wating Timer 20 sec
- IAS mode: OR Dual button from Monitor is pressed.
Timeout : 60sec
-
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
-Boiler Trip - FO Trip - GAS Trip
OR
3
Reset Add Air to Air Flow Controller Timeout : 1sec
4
Reset FG Control Vlv Start Position Timeout : 1sec 5
FO => Dual Seq Failed
- 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
1001854 / 0D / Page 35 of 93
&
Kongsberg Maritime AS
Dual => GAS:
When mode switch is changed from dual to GAS, the system will stop oil firing. SEQ-12 Mode: Dual => GAS
Condition for next step
- FO Press < 3 bar
- FO Burner 1 is OFF - FO Burner 2 is OFF - FO Burner 3 is OFF
Start Start Permissive Terminate
Action Set FO Burner Extinguish Request to FO Flow Controller Timeout: 120sec
- Stop FO Bnr1 (SEQ-4) - Stop FO Bnr2 (SEQ-4) - Stop FO Bnr3 (SEQ-4) if Dual Bnr ON Timeout: 60sec
Error
Error
Reset FO Burner Extinguish Request to FO Flow Controller
- IAS mode: GAS button from Monitor is pressed.OR
- 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
Dual => Gas Sequence Failed
End
1001854 / 0D / Page 36 of 93
OR
Kongsberg Maritime AS
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
FO Auto Backup Order
& OR
Both LD Comp Stop Only Base Gas Bnr Firing No3 Bnr Stop & Gas Mode
‘
1001854 / 0D / Page 37 of 93
Kongsberg Maritime AS
Flowchart for Changeover GAS => Dual: SEQ-13 Mode: GAS => Dual
Condition for next step - Air Bias OK
- FO Control Vlv in Start Pos
- Bnr1 Atm Stm vlv Opened or Bnr1 is OFF & - Bnr2 Atm Stm vlv Opened or Bnr2 is OFF & - Bnr3 Atm Stm vlv Opened or Bnr3 is OFF
Start Start Permissive Terminate
Total Timeout: 5Min
Action
Set Air Bias Timeout : 1sec
Error
Set FO Ctr Vlv To Start Pos Timeout : 10sec
Error
- Open Bnr1 Atm Steam Vlv & - Close Bnr1 Stm Purg Vlv if GAS Bnr1 is ON - Open Bnr2 Atm Steam Vlv & - Close Bnr2 Stm Purg Vlv if GAS Bnr2 is ON
Error
- Open Bnr3 Atm Steam Vlv & - Close Bnr3 Stm Purg Vlv if GAS Bnr3 is ON
- IAS mode: Dual button from Monitor is pressed. - FO Auto backup Order - FG Inc Order (SEQ-9 Step 5, OR SEQ-10 Step 4)
- 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
-Boiler Trip - FO Trip - GAS Trip
Timeout : 10sec
- 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
- FO recirc Valve Close Cmd
- Bnr1 Dual Burning or Bnr1 is OFF & - Bnr2 Dual Burning or Bnr2 is OFF & - Bnr3 Dual Burning or Bnr3 is OFF & Waiting Timer 10sec
- Check Steam Purg Vlv is Closed
Error
Timeout : 10sec
Close FO Recirc Valve Timeout : 10sec
Error
- Open Bnr1 FO Vlv 1&2 if GAS Bnr1 is ON - Open Bnr2 FO Vlv 1&2 if GAS Bnr2 is ON
Error
- 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
End
1001854 / 0D / Page 38 of 93
&
OR
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
Condition for next step - GAS Press < 50mbar
Start Start Permissive Terminate
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 &
- IAS mode: FO button from Monitor is pressed. OR
- 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
&
Error Stop GAS Bnr3
- GAS Burner 3 is OFF Timeout : 30sec
-Boiler Trip - FO Trip
Reset Gas Extinguish Request to Gas Flow Controller
Dual => FO Seq Failed - Reset Gas Extinguish Request to Gas Flow Controller
End
1001854 / 0D / Page 39 of 93
OR
Kongsberg Maritime AS
Low Load Gas Mode:
Low Load This Gas mode be selected dual mode in gas modezone. condition. mode can enables gas onlyeither firinginduring maincondition turbine inor maneuvering
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
4.6 Fuel Oil Boost UP FO boost up sequence is available in GAS mode. The sequence is initiated in case of GAS master valve trip conditions. Start
SEQ-15 Fuel Oil Boost Up
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
Start Permissive Terminate
Action Open: Bnr1 Atm Stm V if Bnr Bnr2 Atm Stm V if Bnr Bnr3 Atm Stm V if Bnr Bnr1 FoVlv1&2 if Bnr Bnr2 FoVlv1&2 if Bnr Bnr3 FoVlv1&2 if Bnr
- Burners Firing in GAS mode - All Bnr FO Valves Closed - FO Shutoff Vlv Opened - Boiler in Auto Mode
firing firing firing firing firing firing
-FO Trip 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
Error
Close Bnr1 FO Vlv's & Air register if No Flame or Purge steam vlv not closed or Atomize steam vlv not open
Force FO Control Vlv to "FO Boost Up Order" Position Timeout: 6 sec
Close Bnr2 FO Vlv's & Air Register if No IR Flame or Purge steam vlv not closed or Atomize steam vlv not open
Wait 15 Sec
- All Bnr GAS Vlv's Closed - Boiler Gas Valve Closed
-FO Boost Up Order From Shd System
Close: - All Bnr GAS Vlv's - Boiler GAS Valve Timeout: 10 sec
Close Bnr3 FO Vlv's & Air Register if No IR Flame or Purge steam vlv not closed or Atomize steam vlv not open Error
Relaease FO Boost Up Order Force Control
Relaease FO Boost Up Order Force Control
Alarm: Fuel Oil Boost Failed
End
1001854 / 0D / Page 42 of 93
&
Kongsberg Maritime AS
4.7 Nitrogen Purge of Gas Supply Lines Purging of gas supply lines can be done from the IAS operator stations. The following sequences are available: •
N2 Purge Master Line to Vent
•
N2 Purge No1/2 Boiler Gas Header to Vent
•
N2 Purge No1/2 Boiler Gas Burner to Furnace( by gas burner stop sequence).
•
N2 Purge No1/2 Boiler Gas Header & Burner to Furnace
Vent Mast Master gas valve
Gas Supply GAS main line N2 purge valve
Vent
Vent
N2 Supply GAS Control
GAS Control
Valve
Valve
Hdr N2 Purge Vlv
Boiler
Boiler
GAS
GAS
Valve
Valve Bnr 3 N2 Purge Valve
Bnr 1 N2 Purge Valve
Bnr 2 N2 Purge Valve
FWD (2)
CNTR (1)
FWD (2) r le i o B d b t S n o s r e
Hdr Vent Vlv
AFT (3)
n r u B
r e il o B t r o P n o s r e n r u B
CNTR (1)
AFT (3)
1001854 / 0D / Page 43 of 93
Hdr Vent Vlv
Kongsberg Maritime AS
4.7.1 N2 Purging of Main Line to Vent When the main line is purged, the line from the master gas valve outlet to each of the boiler gas valve inlets is purged with N2. Master N2 purging can be started when there are no gas burners firing in any boiler, the master gas valve is closed and both boiler gas valves are closed. The system will open the master vent valves and then open the master N2 purge valve. After purge time has elapsed the master N2 purge valve will close again. The main line vent valves will remain open. A status indication “Master N2 purged” will be set after successful sequence is performed. This status will be reset when the master gas valve closed indication disappears. This sequence will be performed automatic when the master gas valve is closed, but can also be manually started from a pushbutton on the IAS operator stations.
Flowchart: SEQ-16 Nitrogen Purging Main Line Condition for next step - Master Gas Valve Closed
Start Start Permissiv e Terminate
- Master N2 purge from monitor(Remote) - Master GAS V alve Close Cmd
Ac tion Check Master Gas Valve Closed Timeout : 50 sec
Error
- Master Vent Valve 1 Opened & - Master Vent Valve 2 Opened
Open Master Vent Valves Timeout : 10 sec
Error
- Master N2 Purge Valve Opened
Open Master N2 Purge Valv e Timeout : 10 sec
Error
- Master GAS V alve Close Command - Boiler 1 GAS Valve Closed - Boiler 2 GAS Valve Closed - No Gas Burners Active
- Master GAS Valve Not Closed
Wait 90 Seconds
- Master N2 Purge Valve Closed
OR
Close Master N2 Purge Valv e Timeout : 10 sec
Error
Master N2 Purge Seq Failed
Set - Master GAS Valve Not Closed
Reset
Set Master N2 Purged Status
End
1001854 / 0D / Page 44 of 93
- Master Vent Valve 1 Open - Master Vent Valve 2 Open - Master N2 Purge Valve Close
&
OR
Kongsberg Maritime AS
4.7.2 N2 Purge of Gas Header to Vent When the gas header is purged, the line from each boiler gas valve outlet to each burner gas valve inlet is purged with N2. The gas header can be purged when no gas burners are firing in that boiler and the boiler fuel gas valve is closed. The system will open the boiler header N2 vent valve and then open the header N2 purge valve. After purge time has elapsed the N2 purge valve will close again. The header N2 vent valve will remain open. A status indication “header purged” will be set. This status will be reset when the boiler fuel gas valve closed indication disappears. This sequence will be performed automatic when the boiler gas valve is closed and purge to furnace is not succeeded. The sequence can be manually started from a software pushbutton on the IAS operator stations if required.
Flowchart: SEQ-17 Nitrogen Purging Boiler Header Condition for next step - Boiler Header N2 Vent Valve Opened
Start Start Permissive Terminate
- Purge boiler hdr/bnr from monitor(Remote) - Boiler GAS Valve Close(SEQ-8,step4)
Open Boiler Header N2 Vent Valve Timeout : 10 sec
Error Error
Open Header N2 Purge Valve Timeout : 10 sec
Error
- Boiler GAS Vlv Closed - All Bnr GAS Closed - Boiler Header N2 Purge Valve Opened
Wait 35 Seconds
- Boiler Header N2 Purge Valve Closed
OR
Action
- Boiler GAS Valve Not Closed
Close Header N2 Purge Valve Timeout : 10 sec
Set - Boiler GAS Valve Not Closed
Error
Set Boiler Header Purged Status
Reset
End
1001854 / 0D / Page 45 of 93
Header N2 Purge Seq Failed - Header Vent Valve Open - Header N2 Purge Valve Close
&
OR
Kongsberg Maritime AS
4.7.3 N2 Purge of Gas Burner to Furnace When the gas burner is purged, the line from each burner gas valve outlet to each gas burner is purged with N2. Burner purge is performed automatically as a part of the gas burner stop sequence (SEQ-6). When the burner gas valve is closed and there is at least one flame in the furnace, the burner N2 purge valve will be opened. After purge time has elapsed the burner N2 purge valve will close again. A status indication “Burner purged” will be set. This status will be reset when the burner gas valves closed indication disappears.
4.7.4 N2 Purge of Gas Header & Burner to Furnace After gas firing is shut off the header and burners are purged to furnace. When the gas header is purged, the line from each boiler gas valve outlet to each burner gas valve inlet is purged with N2. The gas header can be purged when no gas burners are firing in that boiler and the boiler gas valve is closed. The master N2 purge valve and the burner N2 purge valves must also be closed. The system will open all burner gas valves and then open the header N2 purge valve. After purge time has elapsed the N2 purge valve and all burner gas valves will close again. The header N2 vent valve will be opened. A status indication “header purged” will be set. This status will be reset when the boiler fuel gas valve closed indication disappears. This sequence will be performed automatic when the boiler gas valve is closed, but can also be manually started from a software pushbutton on the IAS operator stations.
1001854 / 0D / Page 46 of 93
Kongsberg Maritime AS
Flowchart:
Condition for next step - Boiler Header Vent Valve 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
SEQ-19 Nitrogen Purging Boiler Header & Bnr
Start Start Permissive Terminate
Close Boiler Header Vent Valve Timeout : 10 sec
Error
- Purge boiler hdr from monitor(Remote) - Purge request from Boiler Gas Vlv Close sequence (SEQ-8 step3)
- Any FO Bnr On - Boiler Gas Vlv Closed - All Bnr Gas Valves Closed - Burner N2 Purge Valves Closed
- Open Bnr2 GAS Valves if : FO Bnr2 On
Error
- Boiler Gas Vlv Not Closed
- Open Bnr3 GAS Valves if : FO Bnr3 On
Open Header N2 Purge Valve Timeout : 10 sec
Error
Wait 25 Seconds
- Boiler Header Vent Vlv Opened - All Bnr GAS Valves Closed - Boiler N2 Valve Closed
&
- Open Bnr1 GAS Valves if : FO Bnr1 On
Timeout : 10 sec
- Boiler Header N2 Purge Valve Opened
OR
Action
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
End
1001854 / 0D / Page 47 of 93
- All Gas Bnr Valves Close - Header N2 Purge Valve Close - Header Vent Valve Open
OR
Kongsberg Maritime AS
4.7.5 Main Line Vent Valves Master vent valves are performed automatically as follows.
Master vent valves are automatically closed when: •
10 sec after master gas valve open command
•
Master gas valve open limit switch is active.
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
167B Steam Flow #1
158B Safety Sensor
FI
FI
LI
High Sel
Sel Switch
Boiler Drum
Feed Fwd
LC (PI) LI F1
Setp
FC (PI)
Setp
Par Select
Error
166B Drum Water Level
167B Steam Flow #2
Switch
Fixed level Setp
Backup Controller
LC (PI)
Switch to backup if Feed w flow is faulty
Feed Fwd
Setp
F2
Valve char
FI Economizer Feed Water Pumps
1001854 / 0D / Page 49 of 93
Kongsberg Maritime AS
Failsafe handling Cause
Effect
Comments:
Steam flow signal failure
Steam flow value freeze
Both sensors failed
Feed water flow signal failure
Switch to backup controller
Level measurement signal fail
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.
Difference between valve Command and ABU feedback > 10%
No effect
Alarm
1001854 / 0D / Page 50 of 93
Kongsberg Maritime AS
5.2 Main Steam Temperature Control The purpose of this system is to maintain the main steam temperature constant at set point. The temperature controller set point can be selected from the IAS operator stations. Superheated outlet temperature is measured by two sensors and a high selector is used as process value for the controller. Steam flow and super heater 5 pass inlet temperature is used a feed forward action in order to obtain quick response at load changes. 129B SH Outlet Temp 1
129B SH Outlet Temp 2
TI
119B SH 5 Pass In Temp
TI
TI
167B Steam Flow 1 FI
Hi Sel Steam Flow => Vlv Opening
Steam Temp => Vlv Opening
Normal 515 C
PID
+
FI
FI
Cal Inp => Vlv Min Op.
Hi
Feed Fwd
Setp
Fuel Calorie Input
Hi Sel
Man Mode 500 C
Sw
167B Steam Flow 2
Sel 20%
3rd Burner start 180 s
Hi Sel
0
130B Steam Temp C/V (Large)
1
FO or Dual Mode
133B Small Steam Temp C/V
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
Effect
Comments:
SH Outlet Temp Sensor Failure
Temp Controller to “Manual”
Both sensors failed
SH 5 pass inlet temp sensor failure
Value frozen readable valuein last
Steam flow sensor failure
Value frozen in last readable value
FO flow sensor failure
Value frozen in last readable value
GAS flow sensor failure
Value frozen in last readable value
Both sensors failed
5.3 Atomizing Steam Pressure Control The purpose of this system is to control the atomizing steam pressure at the most suitable levels according to FO pressure. This system consist of a PID controller where set point is derived from the FO pressure.
242B Atom Press
231B FO Press
PI
PI
DO Press => Atom Setp
FO Press => Atom Setp
PID
Swit ch
Ign Val FO (6bar) FO Bnr's Off
Swit ch
DO Use
Swit ch
Ign Val DO (6bar) FO Bnr's Off
Setp Follow
Tracking 50% at Gas Mode
226B Atomiz Press C/V
1001854 / 0D / Page 52 of 93
Kongsberg Maritime AS
Failsafe handling Cause
Effect
Atom Press signal fault
Controller is set to “Manual”
Comments:
FO press signal fault
No effect
5.4 Steam Purge Pressure Control The purpose of this system is to control the purge steam pressure at the most suitable levels. 362B Purge Press 2bar 1bar
PI 0
1
2bar
0
1
Burner Purge SP down at Burner Purging (SEQ-4 Status 8-12)
Any Burner Purge V/V Open
Setp
PID
Failsafe handling Cause
Effect
Comments:
Purge Press signal fault
Controller is set to “Manual”
1001854 / 0D / Page 53 of 93
Kongsberg Maritime AS
5.5 FO Pump Discharge Pressure Control The FO pump outlet pressure is maintained by controlling the recirculation. Set point to the controller is a high selection of main boiler 1 and main boiler 2 FO burner pressure.
MB1 FOPress (from Fuel Oil Control Loop)
MB2 FOPress (from Fuel Oil Control Loop)
200B FOPump Press PI
Hi Sel FO Press => Setpoint
All FO Bnr Stopped (8,5bar)
Setp
Switch
PID
FO Pump Stopped (80%) Switch
FO Boost Seq Run
10% 20 s
215B FOPump Press C/V
Failsafe handling Cause
Effect
FO pump pressure signal fail
Controller is set to “Manual”
MB1 FO pressure signal fail
No effect
If both boiler FO press signal fails then set point will be fixed.
MB2 FO pressure
No effect
If both boiler FO press signal fails then
signal fail
Comments:
set point will be fixed.
1001854 / 0D / Page 54 of 93
Kongsberg Maritime AS
5.6 Steam Pressure Control The purpose of this system is to maintain the steam pressure at outlet super heater at a constant value according to set point, normally at 60.3 bar. Set point is adjustable from IAS operator stations. The pressure control is done by controlling the total fuel flow and the combustion air flow to all burners. The air flow controller will lead during increasing demand At boiler start, steam up controller will bring boiler pressure up to set point at predefined rate. When 2 boilers are brought up to set point (steaming up finished) the master controller will automatically activate and take control.
Boiler Master Controller.
The boiler master controller consists of 3 controllers. • Boiler 1 controller: - Steaming up, 1 boiler operat ion, FO ,Gas or air flow in manual. • Boiler 2 controller: - Steaming up, 1 boiler operat ion, FO ,Gas or air flow in manual. • Master controller: - 2 boilers parallel operation and FO ,Gas and air flow in auto.
Load ratio A load ratio function is applied at master control. Operator may select a percentage load rate between the two boilers. This will affect the master calorie demand to FO, Gas and air flow controllers.
Master Set point.
Master set point is set manually, normally 60.3 bar. Dump controller set point is given a bias from master set point, normally master set point + 1 bar. In case of maneuvering mode or excess BOG mode master set point is automatically set down to master set point – 1 bar (set down ramp is rapid, return to master ramp is slow).
1001854 / 0D / Page 55 of 93
Kongsberg Maritime AS
165B MB1 Sream Press 1
165B MB1 Steam Press 2
PI
PI
165B MB2 Steam Press 1
PI
Hi Sel
165B MB2 Steam Press 2
167B MB1 Steam Flow 1
167B MB1 Steam Flow 2
167B MB2 Steam Flow 1
167B MB2 Steam Flow 2
PI
FI
FI
FI
FI
Hi Sel
Hi Sel
Hi Sel
Swit ch
Steam Up Rate Master Setpoint Auto Set Down Set Down Bias
d w dF ee
Set
PID
Trc
Swit ch
Hi Sel
F
Set
PID
Gas Cal Input
+
0-50 Gcal/h
Bias 1.1
+
MB2 Master Demand
Ratio Set Ratio Feedback 0-50 Gcal/h
Swit ch
Other Boiler
Low Load Gas Mode Tracking Master : NOT (2 boiler paralell operation and FO,GAS,Air in Auto)
0.00075 Gcal/kg Air Flow (kg/hr)
d w
Trc
Load Ratio
Low Lim
Press => Max Load
F ed Fe
Master 0-100 Gcal/h
Steam-Up
0-50 Gcal/h FO Cal Input
Hi Sel
*
Low Sel
* 0,5
Low Lim
Steam Up: FO or GAS or Air i n Manual or Master Active
Boiler Demand
Failsafe handling Cause
Effect
Comments:
MB1 steam pressure signal failed
Controller is set to “Manual”
Both signals failed
MB2 steam pressure signal failed
Controller is set to “Manual”
Both signals failed
MB1 steam flow signal failed
Valuefreeze
Bothsignalsfailed
MB2 steam flow signal failed
Valuefreeze
Bothsignalsfailed
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
231B FO Press 2
PI
To Atomiz Press Control Loop To FO Pump Discharge Press Control Loop
PI
HI Sel
Swit ch
A Swit ch
All FO Bnr Off 0
Gas Flow (from Gas flow control loop)
Master Cal Demand Gas Cal Input 0 FO Boost Up Order
FG Flow => FO Flow
FO Press => FO Flow
Swit ch
Lo Sel
X
/
With Up/dwn Ramp
X
No Of FO Bnr
-
Swit ch
&
OR
2nd FO Ign Set Req 3rd FO Ign Set Req Dual Mode
Max FO Bnr Flow No Of FO Bnr
FO Cal Value
FO Bnr Exting Req
A
PID
Min Press Control
Hi Sel Swit ch
FO Flow FO Cal Inp X
PID
FO Cal Value
Lo Sel
FO Boost Up Order
Swit ch
FO Ctr Vlv Force Swit ch
Setp
FO Cal Value
FO Recirc Vlv Opened FO Ignition , FO FO Ignition, Dual 1bnr FO Ignition, Dual 2bnr FO Ignition, Dual 3bnr
1001854 / 0D / Page 57 of 93
X
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
Kongsberg Maritime AS
Failsafe handling Cause
FO press signal failed Gas press signal failed
Effect
Comments:
Manual mode
Both sensor failed
No effect
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
249B Gas Press
238B BOG Temp
230B BOG Press
TI
PI
PI
Gas Press => Gas Flow Master Cal Demand
X
FO Min Cal Input FO Cal Input
X
Swit ch
-
No Of Gas Bnrs
FO control Manual Gas Control Manual
OR
OR
&
2nd FO Ign Set Req 3rd FO Ign Set Req Dual Mode
Lo Sel Swit ch
0
X
Max Gas Bnr Flow No Of Gas Bnr
All Gas Bnr Stop
/ To Air Flow Control To Fuel Oil Flow Control
With Up/Dwn Ramp Flt
Gas Flow
Swit ch
Gas Cal Value
Gas Bnr Exting Req
Gas Cal Inp
Hi Sel
X
Min Gas Flow 1 Bnr
Swit ch
Min Gas Flow 2 Bnr Min Gas Flow 3 Bnr Min Gas Flow At Bnr Inc
Gas Cal Value
PID
Min Flow Controller
Setp
Flow Controller
Hi Sel
FO Boost Up Order
Swit ch Gas Shut Vlv Closed Gas Ignition, 1bnr, Free Flow
Gas Ctr Vlv Force
Gas Ignition, 2bnr, Free Flow
Swit ch
Gas Ignition, 3bnr, Free Flow Gas Ignition, 1bnr, LD Run Gas Ignition, 2bnr, LD Run Gas Ignition, 3bnr, LD Run
208B Gas Flow C/V
1001854 / 0D / Page 59 of 93
PID
Kongsberg Maritime AS
Failsafe handling Cause
Effect
Comments:
Gas press signal failed
Switch to flow control
BOG press signal
No effect
failed BOG temp signal failed
No effect
GAS Flow signal failed
Switch to pressure control
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
FO Flow
GAS Flow
Flue Gas O2
Burner Load
O2
17.47
X
14
Air Flow PI
+
PI Hi Sel
Bnr Load => O2 Content
X
Air Flow
Calc
Sel
Stby Fan
Sw
Air Fl ow
mbar => Kg/h
A Excess R atio
X Fuel/Air Ratio Set 0.5 - 1.5
X
Soot Blow Running 1.1
X
Air Bias ( Bnr Seq) 1.05
X
Not Man Zo ne Steam Flow > 80% 3 Bnr Run
Setp
1 w lo ol F
.0
PID Range 0.9-1.1 Setp
> 40000
Furn Prg OK
> 4000 & < 8000
Ign OK
PID
& Sw i tch
Ignition Set Furn purge Fdf Stop
Vane Char
X 1 bnr On (1.05) 2 bnr On (1.03)
Sw i tch
X
3 bnr On (1.00) Boiler Master
Note:
+ A
X2
Low Sel
O2 trim control is activated when the following conditions are established: Steam flow > 80% & 3 burners firing.
Failsafe handling Cause
Effect
Comments:
Air flow sensors failed
Air flow controller to manual
Both sensors failed
FO press signal failed Gas press signal failed
No effect No effect
O2 Sensor failed
O2 trim is bypassed
1001854 / 0D / Page 61 of 93
Kongsberg Maritime AS
5.7 Steam Dump Control The main purpose of this system is to force the boilers to burn excess boil of gas generated in the cargo tanks. Secondary function is to prevent overpressure in the boilers. In case pressure at the steam outlet is above set point, the steam dump valves will start to open dumping the excess steam to the main condenser Excess BOG Controller.
FO flow and Recommended BOG rate is calculated and transformed to an estimated steam flow equivalent which will be defined as the controller set point. The controller will use the dump control valves to keep the steam flow at set point.
Max Gas Valve Controller.
The excess dump controller output will be limited in case Gas control valve exceeds the max value (90%).
Maneuver Dump Controller.
Set point of this controller is made by master controller set point + bias. The controller will remain passive until boiler pressure exceeds the set point. When controller is activated it will remain active until boiler pressure is normal and output is 0.
1001854 / 0D / Page 62 of 93
Kongsberg Maritime AS
167B MB1 Steam Flow
167B MB2 Steam Flow
FI BOG DUMP MODE
&
GAS BNR RUNNING
Lo Sel
+
MB2 Min FO Flow
PI
Hi Sel
Hi Sel
=> Stm Flow Set
PID
Dump PID Controller
BOG Controller
Load Limit
Hi Sel
MB2 FG Vlv Pos
Hi Sel
Lo Sel
Swit ch
PID t Se
Max FG Vlv Pos 95%
Dump Order => Spary V1 Contr
165B MB2 Steam Press
GCal
Swit ch
Rec BOG 0-130 t/h
MB1 FG Vlv Pos
PI
FI
Not
0
MB1 Min FO Flow
165B MB1 Steam Press
Max FG Controller
Swit ch
0
Set
Crash Ast Boiler Master
MT Trip
Dump Pist Vlv Closed Dump C/V Lead/Follow Change Over
Dump Order => Spary V2 Contr
0
1
Master Setpoint Bias 1bar
+
Hardware Function Generator by MHI
0
1
0
1
0
1
To IAS for Spray Vlv Control 331B Dump C/V #1 332B Dump C/V #2
Valv e Outpu t 10 0
Spray1
90
Spray2
Dump1
Dump2
80
70
60
50 40
30
20
10 Dump Controller Output 10
20
30
40
50
60
70
80
90
1 00
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%
&
Off Delay 3min
OR
MT manovering zone MT Trip
Dump Available From IAS
Failsafe handling Cause
Effect
Comments:
Steam press sensors failed
Controllers is set to “Manual”
4 sensors failed
Steam flow sensors failed
No effect
MB1 Gas control vlv pos feedback failed
No effect
MB2 Gas control vlv pos feedback failed
No effect
MB1 FO flow signal failed
No effect
MB2 FO flow signal failed
No effect
1001854 / 0D / Page 64 of 93
Dump Piston Vlv Open Order
Kongsberg Maritime AS
5.8 Flame Eyes There are four flame eyes for each of the burners. Two flame eyes for both IR sensing and two for UV sensing. Flame is detected if one of the flame eyes is activated. When FO burning or GAS burning is active, then if one flame failure is detected then one flame eye fail alarm is provided. If four flame eyes failure are detected then FO and GAS burners are tripped. (Refer to "6 BOILER TRIP") IR flame fail alarm is suppressed if burner is only gas firing. UV flame fail alarm is suppressed if burner is FO or dual firing. Flame eye rack “power fail” and “fan failure” is sent to ABC for alarm.
Principle drawing:
Timer Off 0 sec Flame Scanner 1 IR On Flame Scanner 2 IR On OR
Flame Scanner 1 UV On
Flame ON
Flame Scanner 2 UV On
FO burner burning
& OR
GAS burner burning
Timer On
& All Burner Stopped
1001854 / 0D / Page 65 of 93
OR
F/E #1 IR Abnormal
Kongsberg Maritime AS
5.9 FDF STBY Fan Each main boiler has it’s own FDF which is normally used for combustion air supply. In addition there is a stby FDF which can be used in case normal FDF is failed. The stby FDF is common for the two boilers and can be used for only one boiler at the time. The ABC receives certain inputs for detecting that sbty fan and damper is selected and OK. Air flow sensors for stby FDF is input to common FS and the ABC logic will use these sensors for air flow control when stby FDF is selected. The output for vane control is switched to stby FDF vane by hardwired logic by MHI
No1 STBY Fan Mode No1 Side STBY Fan Dmr Open
No1 STBY Fan Mode(DO)
&
STBY FDF Run Low Or High OR Normal FDF Run
Blr FDF Run
1001854 / 0D / Page 66 of 93
Kongsberg Maritime AS
5.10 Hot Start Valve At hot start of boiler (steam press < 15 bar) the start-up valve is opened.
When steam flow is low at boiler hot start (Steam up controller active) the start up valve is controlled according to steam flow.
After steam up is finished the start up valve is permanently closed.
Boilercondition
Steamupvalve
Closed
Boiler stopped
No burners firing Opened
Cold start of boiler
Cold start needle valve opened & Boiler firing & steam press < 15bar Opened
Hot start of boiler
Boiler firing & steam press > 15bar & steam flow < 2.5 t/h Closed
Hot Start of boiler
Boiler firing & steam press > 15 bar & steam flow > 4 t/h Set
Boiler Firing Staem Press < 15 bar
&
Staem Press > 15 bar
&
OR
Reset
RS
Steam Flow < 2.5 t/h
OR
Staem Flow > 4.0 t/h
&
Timer ON 3 min
1001854 / 0D / Page 67 of 93
Hot Start Valve Open Order
Kongsberg Maritime AS
5.11 Viscometer Outlet Valve When total (No.1 and No.2) FO flow is less than 900kg/h or No.1 boiler is gas mode or No.2 boiler is gas mode, viscometer outlet valve is opened. 1200 kg/hr
No.1 Blr FO Flow
+
LSE
No.2 Blr FO Flow No.1 Blr Gas Mode
Set 1200kg/hr Reset 1700 kg/hr
OR
No.2 Blr Gas Mode
1001854 / 0D / Page 68 of 93
Viscometer Valve Open
Kongsberg Maritime AS
5.12 Fuel/Atomizing Valve Abnormal HFO supply manual valve close LS DO supply manual valve close LS Atomizing steam supply manual valve close LS Atomizing air supply manual valve close LS
No. HFO
DO
Steam
Air
Remark
Close
Close
Close
Close
1
X
X
X
X
Alarm
2
X
X
X
O
Alarm
3
X
X
O
X
Alarm
4
X
X
O
O
Alarm
5
X
O
X
X
Alarm
6
X
O
X
O
Normalcase1(Hotstartcondition)
7
X
O
O
X
Normalcase2(Transitioncondition)
8
X
O
O
O
Alarm
9
O
X
X
X
Alarm
10
O
X
X
O
Trip case
11
O
X
O
X
Normalcase3(Coldstartcondition)
12
O
X
O
O
Alarm
13
O
O
X
X
Alarm
14
O
O
X
O
Alarm
15
O
O
O
X
Alarm
16
O
O
O
O
Alarm
X: open, O: close In case of No.10, FO shut off valve will be closed. In case of No. 6,7 and 11, condition is normal. In other case, alarm will be set.
1001854 / 0D / Page 69 of 93
Kongsberg Maritime AS
5.13 Output to Main Turbine The boiler control calculates some outputs for the main turbine system. Main B oiler 1
Drum Water Level Transmitter
CompHi 220mm
10 s
CompHi 200mm
10 s
CompHi 180mm
10 s
CompLo -200mm
10 s
MT Trip
MT Slow dow n
MT Program Interlock
MT Slow dow n
Main B oiler 2
Drum Water Level Transmitter
CompHi 220mm
10 s
CompHi 200mm
10 s
CompHi 180mm
10 s
MT Trip
MT Slow dow n
MT Program Interlock
10 s
CompLo -200mm
MT Slow dow n
Boiler C om m on
MB1 Logick
Boiler Firing
&
MB2 Logick
Both Boiler Trip
&
Boiler Firing
OR
&
1001854 / 0D / Page 70 of 93
One Boiler Trip
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
Action
Reset
Atomizing steam press LL (3bar)
- Boiler FO Shut Vlv Close
FO temp LL (have bypass switch) (80 deg/C)
- No1 burner FO vlv1&2 Close
Acknowledge pushbutton and
FO Press LL (1bar)
- No2 burner FO vlv1&2 Close
FO Pump Stop Fuel/Atomize Valve Abnormal
- No3 burner FO vlv1&2 Close
1001854 / 0D / Page 71 of 93
Boiler FO shutoff vlv close pushbutton
Kongsberg Maritime AS
Logic Diagram. Atm Steam Pres s 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
Set
FO Trip OR Boiler trip Control position IAS IAS Blr FO Shutoff Vlv Close Push button
Reset
RS
Bnr1 FO Vlv1&2 Shu tdow n Order Bnr2 FO Vlv1&2 Shu tdow n Order
& OR
Control position BGB BGB Blr FO Shutoff Vlv Close Push button
BoilerFO Shutoff Vlv Shutdow n Order
&
1001854 / 0D / Page 72 of 93
Bnr3 FO Vlv1&2 Shu tdow n Order
Kongsberg Maritime AS
Boiler Trip.
In case boiler trip condition occur is both FO and Gas system is tripped. Cause
Action
Reset
Drum water level HH (+240mm
- Activate FO trip
Acknowledge push-
+ 10s) by analogue sensor Drum water level LL (-240mm) by switch OR
- Activate Gas trip
button and Boiler FO shutoff vlv close pushbutton resets FO trip
Drum water level LL (-240mm + 5s) by analogue sensor FDF stop
Acknowledge pushbutton and
All burner flame fail Emergency manual trip ECR
Boiler Gas vlv close push-button reset Gas trip.
Emergency manual trip BGB Main steam temp H (545deg/c) by analogue sensor
1001854 / 0D / Page 73 of 93
Kongsberg Maritime AS
Drum Water Level Transmitter
CompHi 240mm
10 s
CompLo -240mm
5s
OR
Drum Water Lev el LL Float Sw itch
Boiler Trip
No1 FD Fan Run
&
Stby Fan Mode On
OR
Stby FD Fan Run High or Low
OR &
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 Action Reset BOG Press L (7mbar)
- Boiler Hdr Vent Vlv Open
BOG Press H (736mbar)
- Boiler Gas Shut Vlv Close
Boiler Trip Condition
- No1 burner Gas vlv1&2 Close
Master Gas Valve Trip On + 15s
- No2 burner Gas vlv1&2 Close - No3 burner Gas vlv1&2 Close
1001854 / 0D / Page 74 of 93
Acknowledge pushbutton and Boiler Gas shutoff valve close pushbutton
Kongsberg Maritime AS
BOG Press Transmitter
CompLo 0,007bar
&
CompHi 0,736bar
&
90 s
OR Any Bnr Gas V lv Opened
Boiler GAS Trip
10 s
Boiler Trip On 15 s
Master GAS Vlv Trip On
Set
GAS Trip OR Boiler trip
Reset
RS
Boiler Vent vlv Open Order Boiler GAS Vlv Shutdow n Order Bnr1 GAS Vlv1&2 Shu tdow n Order
Blr GAS Vlv Close Pushbutton
Bnr2 GAS Vlv1&2 Shu tdow n Order Bnr3 GAS Vlv1&2 Shu tdow 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
Action
Reset
E/R Vent Fan Failure
- Master GAS Vlv Shutdown
Gas Duct Exh Fan Stop
- Master N2 Vent Vlv Oppen
Acknowledge pushbutton and Master GAS Vlv close push-button
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
1001854 / 0D / Page 75 of 93
Kongsberg Maritime AS
E/R Vent Fan Failure Gas Duct Exh Fan Stop
On-delay
10 s
FO Boost Up Order
Gas Leak Detected Fire detected BOG Temp LL
Master GAS Vlv Trip Master Gas Vlv Manu Trip (ECR)
OR
OR
Master Gas Vlv Manu Trip (BGB) Vapour Hdr Press LL BOG Htr Abnormal Master Gas Vlv Close PB
Both Boiler Trip Both Blr GAS Vlv's Closed LS GAS Master Vlv Trip
Set Reset
RS
GAS Master Vlv Close Pushbutton
1001854 / 0D / Page 76 of 93
Master Vent vlv Open Order Master GAS Vlv Shutdown Order
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
Set Reset
& IAS Base Bnr OFF PB
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
Set Reset
& IAS No.2 Bnr OFF PB
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
Set Reset
& IAS No.3 Bnr OFF PB
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
& BGB No.3 Bnr OFF PB
&
Base Bnr Flame ON
&
No.2 Bnr Flame ON No.3 Bnr Flame ON &
1001854 / 0D / Page 77 of 93
OR
All Bnr Flame Fail
Kongsberg Maritime AS
7 BOILER OPERATION PANELS 7.1 BGB Graphic Panel The BGB The graphic panelactivates containsthe buttons control as of those sequences and lamps for from feedback. buttons same for sequences used when operating the IAS operator stations.
Command transfer.
In order to use the functions from the panel, command must be transferred from the control room to the BGB.
BGB graphic panel lamp and switch functions.
Description
Type
Function
Orginator
By-pass Condition No1 or No2 Emerg Mode
MB1 + MB2
Lamp
Switch on BGB for selection of “Emergency Mode”
BGB (by MHI)
Common Emerg Mode
MB1 + MB2
Lamp
Switch on BGB for selection of “Emergency Mode”
BGB (by MHI)
AC 220V Source DC 24V Source
MB1 + MB2 MB1 + MB2
Lamp
Lamp
Lamp on BGB Lamp on BGB
BGB (by MHI) BGB (by MHI)
NoX Burner NoXGasBNROn
MB1x3+ MB2 x 3
Switch/Lamp Swich: Starts GAS Burner when Local Contr Position & manual mode.
FS-10(MB1), FS-11(MB2)
Lamp: - Flicker during start seq, - Fast Flicker when start error - Steady when burner is On NoXGasBNROff
MB1x3+ 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
1001854 / 0D / Page 78 of 93
FS-10(MB1), FS-11(MB2)
Kongsberg Maritime AS
Description NoXFOBNROn
Type MB1x3+
Function
Orginator
Switch/Lamp Swich: Starts FO Burner when Local Contr Position &
MB2 x 3
manual mode.
FS-10(MB1), FS-11(MB2)
Lamp: - Flicker during start seq,
- Fast Flicker when start error - Steady when burner is On NoXFOBNROff
MB1x3+
Switch/Lamp Swich: Stops FO Burner when Local Contr Position &
MB2 x 3
manual mode. Also reset of start/stop error
FS-10(MB1), FS-11(MB2)
Lamp: - Flicker during stopt seq, - Fast Flicker when stopt error - Steady when burner is On FlameSignal
MB1x2+
Indicator
Indicator
Flameconditionindicator
BGB(byMHI)
MB2 x 2
FO Shut V/V Open
MB1 + MB2
Switch/Lamp Swich: S end open command to FO shut valve Lamp: - Flicker during open time,
FS-10(MB1), FS-11(MB2)
- 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
FS-11(MB2)
Lamp: - Flicker during close time, - Fast Flicker if close failed - Steady when valve is closed
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)
InProgress
MB1+MB2
Lamp
LampOn:Furnacepurgeinprogress
FS-10(MB1), FS-11(MB2)
Complete
MB1 + MB2
Lamp
LampOn: Furnace purge compleate OR Purge Status
1001854 / 0D / Page 79 of 93
FS-10(MB1),
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
FS-10(MB1), FS-11(MB2)
Lamp: Burner operation at BGB On IAS
MB1+ MB2
Switch/Lamp Switch:C hangeburner operationtoIAS Lamp
FS-10(MB1), FS-11(MB2)
Burner operation at IAS On
Al arm BoilerTrip
MB1+MB2
Lamp
Boilertripactiveornorreset
FS-10(MB1), FS-11(MB2)
Atm Press Low
MB1 + MB2
Lamp
Atm press low active
FS-10(MB1), FS-11(MB2)
FOPressLow
MB1+MB2
Lamp
FOpresslowactive
FS-10(MB1), FS-11(MB2)
Manualtrip
MB1+MB2
Lamp
BoilerManualTripactive
FS-10(MB1), FS-11(MB2)
AB C Pos it io n 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: Changecontrol loopoperationtoIAS Lamp
GASFiring
MB1+MB2
Lamp
Control loop operation at IAS On
GASfiringcondition
FS-10(MB1), FS-11(MB2) FS-10(MB1), FS-11(MB2)
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
1001854 / 0D / Page 80 of 93
FS-10(MB1), FS-11(MB2)
Kongsberg Maritime AS
Description
Type
Function
Orginator
- Steady when valve is open Close
MB1 + MB2
Switch/Lamp Switch: Send close command to feed water motor valve control panel.
FS-10(MB1), FS-11(MB2)
Lamp: - Flicker during close time - Fast flicker if closed failed - Steady when valve is closed FS-10(MB1), FS-11(MB2), FS12,(Com) FDF Start
MB1 MB2 + +
Switch
Switch: Send start command to group starter panel via
Switch
Switch: Send stop command to group starter panel via
Common Stop
MB1 MB2 + +
IAS.
Common Run
MB1 MB2 + +
IAS. Lamp
Lamp: Steady when FDF is Running.
Switch
Switch:S endstartcommandtogroupstarterpanelvia
Common
Aux Feed Water Pum p Start
Common
FS12,(Com)
IAS. Stop
Common
Switch
Switch:S endstopcommandtogroupstarterpanelvia
FS12,(Com)
IAS. Run
Common
Switch
Lamp: SteadywhenmotorisRunning.
FS12,(Com)
Seal Ai r Fan Run(No1/2)
Common
Lamp
Lamp: SteadywhenfanisRunning.
1001854 / 0D / Page 81 of 93
FS12,(Com)
Kongsberg Maritime AS
7.2 Manual Loader Functions The graphic panel at the BGB contains functions for manual control of each control valve. The IAS output (4-20mA) for control valves are connected to an ABU (Analogue Backup Unit).
Normal mode.
Each control valve or FDF vane can be manually controlled from either BGB graphic panel or from IAS operator stations. In normal mode the 4-20mA control signal from IAS is passed to the actuator. (Except for purge C/V and small Steam temp C/V)
Emergency mode.
In this case the IAS 4-20mA control signal is neglected and BGB increase/decrease order is operating the ABU output directly.
The following control loops can be controlled from the local control panels • Control of atomizing stem control valves.(MB1 & MB2) • Control of the super heater temperature control valves.( MB1 & MB2) • Control of Fuel gas control valves. (MB1 & MB2.) • Control of the fuel oil control valves. (MB1 & MB2.) • Control of the fd-fan inlet vanes. (MB1 & MB2) • Control of the feed water valves. (MB1 & MB2.) • Control of dump control valve (common for both boiler) • Control of FO pump pressure control valve (common for both boilers)
Note: ABU units are MHI supply.
1001854 / 0D / Page 82 of 93
Kongsberg Maritime AS
ABC Po si ti on IAS
Set
BGB
Reset
IAS
RS Not
OR
BGB
Emerg mode
Manual/Auto Se lectio n ABC Position "BGB"
Set &
OR
BGB A
Auto
RS
Reset
Not
Manual
&
BGB M
OR
ABC Position "IAS" &
IAS A (Sow button)
&
IAS M (Sow Button) Emerg mode
Inc / Dec Prinsipple Manual
c Tr
Man/Auto Selection "Manual" ABC Position "BGB"
&
lec Se
PID t
Tr
c
Va lu e
+ -
&
+/-
Inc
& Dec Emerg mode ABU Feedback(4-20mA)
Sel Sw
Output to ABU 4-20mA
1001854 / 0D / Page 83 of 93
Kongsberg Maritime AS
7.3 Emergency Operation Note: This is outside of IAS, MHI supply
7.3.1 No.1 or No.2 part case of failure of both controllers (active/standby) for No.1 or No.2 part, emergency operation mode is performed in following manner. 1)
Air flow control valve should be fully closed. And the forced draft fan shall be started.
2)
If emergency mode switch for common part is selected to emergency mode then FO pump discharge press control valve should be opened at about 50%. And the FO burning pump shall be started. After starting of FO burning pump, FO pump discharge press should be adjusted at a suitable pressure (15-20bar).
3)
Change operation mode switch from "NOR" to "PURGE". Open fully (above 70%) air flow control valve. Differential press between wind box and furnace should be confirmed (above 15mbar). Furnace purge should be conducted until turning "Purge Finish" lamp on.
4)
Change emergency mode from "PURGE" to "BURN".
5) 6)
Air flow control valve should be set at ignition position. (About 5%) FO flow control valve should be set at ignition position. (About 20%)
7)
Atomizing press control valve should be set at suitable position. (About 30%)
8)
Turn FO shut V/V switch from "CLOSE" to "OPEN".
9)
Turn igniter switch from "OFF" to "ON".
10) Turn FO V/V switch from "CLOSE" to "OPEN". FO V/V "OPEN" position should be kept until establishment of flame. However, it must not exceed 10 seconds. 11) Atomizing press should be kept at 8bar. 12) FO and Air flow should be adjusted manually, to keep safe combustion. 13) When second burner start, fuel oil press should be exceeded 10bar. And same as above item 12) and 13).
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.
1001854 / 0D / Page 84 of 93
Kongsberg Maritime AS
7.3.2 Common Part In case of failure of both (active/standby) controllers for common, emergency operation mode is performed in following manner. 1) Change operation mode switch from "NOR" to "EMERG". 2) FO pump discharge press should be adjusted at suitable pressure (15-25bar). 3) If dump control is needed, dump control valve should be adjusted at a suitable position.
8 SOOT BLOWING SEQUENCES The soot blower sequences are provided within the IAS. Operations are done from the IAS monitors. Each boiler are equipped with 2 sequence possibilities, “Boiler & economizer” or “economizer”. In addition each blower can be started locally. The software consists of many subsequence’s, one for each blower. A main sequence call up respective subsequence during auto operation. Local operation call each subsequence directly.
Operation.
Operation is done from IAS monitors. Following operation modes are prepared: • “NO1 MAIN BOILER” • “NO2 MAIN BOILER” • “BOTH BOILERS”
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.
1001854 / 0D / Page 85 of 93
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 subsequence’s “Long Soot Blower” and “Rotary Soot Blower” as described below is activated directly by the operator.
1001854 / 0D / Page 86 of 93
Kongsberg Maritime AS
8.1 Long Soot Blower Sequence This sequence can be called from “SEQ START” sequence or by local command. The blower will first run fwd until retract position is received. Then reverse rotation order is active until stop limit switch is received. An emergency retract function is applied. If emergency retract command is activated the run fwd order is cancelled and retract order is activated. Retract order will remain until stop limit switch is received. A maximum timer for retract order is applied. Start
Condition for next step - Blower Fwd Running ON & - Stop position OFF
- Blower Retract Position ON & - Blower Fwd Running OFF
- Blower Rev Running ON & - Retract Position OFF
- Blower Stop Position ON - Blower Rev Running OFF
Start Start Permissive Terminate
- Start Req from Soot Blow Auto Seq - Start Req from Local.
OR
Action Start Fwd Timeout : 5 sec
Reset Fwd Start at Retract position
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
Timeout : 250 sec
Start Reverse
&
Error
Timeout : 5 sec
Reset Rev Start at Stopt position
- Emergency Retract ON - Steam press low & 30 Sec After Vlv Open - Steam supply valve abnormal if Auto Seq OR - Boiler trip
Error
- Auto Seq Fail - Motor Overload
Timeout : 250 sec
- Reset Run Fwd Order - Set Rev Order if not stop position - Set Alarm - Set Bypass if Auto Seq
End
8.2 Rotary Soot Blower Sequence This sequence can be called from “SEQ START” sequence, “ECO START” sequence or by local command. The blower will run until stop position is received. Then run order will be switched off.
1001854 / 0D / Page 87 of 93
Kongsberg Maritime AS
Start
Condition for next step - Blower Running ON & - Stop Position OFF
- Stop Position ON & - Blower Running OFF
Start Start Permissive Terminate
- Start Req from Soot Blow Auto Seq - Start Req from Local.
OR
Action Start Blower Timeout : 5 sec
Error
Stop Blower at Stop position Error Timeout : 60 sec
- Motor Overload - Boiler Load < 50 %
- Motor Overload - Boiler Trip - Auto Seq Fail
&
OR
- Reset Run Order - Set Alarm - Set Bypass if Auto
End
8.3 Boiler & Economizer Soot Blower Sequence This sequence makes use of “Long soot blower sequence” and “rotary soot blower sequence” in order to make a complete soot blower sequence. Each boiler can be soot blower separately or both boilers can be blower in serial. Once Steam supply valve opens, this valve keep open until all sequence finish AND all long soot blower in normal stop position. When long soot blower is stuck in travelling, steam supply valve keep open.
1001854 / 0D / Page 88 of 93
Kongsberg Maritime AS
Flowchart for No.1 or No.2 boiler sequence Start Start Permissive Terminate
Start
Condition for next step - Steam Vlv Opened
Open Steam Vlv Timeout : 40 sec
- Control position IAS - No1 or No2 Boiler Select
Timeout : 10 sec
Error
Timer 180s
- Steam Press OK
- 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
Check Steam Pressure OK Timeout : 2 sec
Error
Start L1 If not Bypass ON Timeout : 2 sec
Bypass
Wait, L1 blowing Timeout : 500 sec
Error
Start L2 If not Bypass ON Timeout : 2 sec
Bypass
Wait, L2 blowing Timeout : 500 sec
Error
Start R1 If not Bypass ON Timeout : 2 sec
Wait, R1 blowing Timeout : 60 sec
Error
Bypass
Wait, R2 blowing Timeout : 60 sec
Error
Wait, R3 blowing Timeout : 60 sec
- Emergency Retract ON - Steam press low & 30 sec after eam valve open - St eam supply valve abnormal - Boiler Trip - AC 440V Failure
Bypass
Start R2 If not Bypass ON Timeout : 2 sec
Start R3 If not Bypass ON Timeout : 2 sec
Not other ECO START -- Not 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 %
Bypass
Error
Start R4 If not Bypass ON Timeout : 2 sec
Bypass
Wait, R4 blowing Timeout : 60 sec
Error
Start R5 If not Bypass ON Timeout : 2 sec
Bypass
Wait, R5 blowing Timeout : 60 sec
Error
- R6 Seq Run OR - Bypass ON
Start R6 If not Bypass ON Timeout : 2 sec
Bypass
- Terminate all soot blower sub sequences
- R6 Seq Not Run
Wait, R6 blowing Timeout : 60 sec
Error
- Close steam Vlv if all long blower in normal stop position
Close Steam Valve if all long blower in normal stop position & Open Drain Vlv 1&2 Timeout : 10 sec
Error
- Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
OR
Error
Close Other Blr Drain Valve - Other Boiler Drain Valve Closed
- Start from Monitor(IAS)
Action
- Open No1 MB Drain Vlv - Open No2 MB Drain Vlv - Set Alarm
End
1001854 / 0D / Page 89 of 93
&
OR
Kongsberg Maritime AS
Flowchart for both boiler sequence Start
Condition for next step - Steam Vlv Opened &
Start Start Permissive Terminate
- Start from Monitor(IAS)
OR
Action Open Steam Vlv Timeout : 40 sec
Error
Close No.2 Blr Drain Valve Timeout : 10 sec
Error
- Control position IAS - No.2 Blr Drain Valve Closed
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec
Error
No1 Boiler Blower Sequence L1,L2,R1,R2,R3,R4,R5,R6
- No.2 Blr Drain Valve Opened
Open No.2 Boiler Drain Vlv Timeout: 10 sec
Error
- 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 %
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam s upply valve abnormal - Boiler trip - AC 440V Failure
&
OR
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec
Error
No2 Boiler Blower Sequence L1,L2,R1,R2,R3,R4,R5,R6 - 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
8.4 Economizer Soot Blower Sequence This sequence makes use of “rotary soot blower sequences” in order to make a complete soot blower sequence. Each boiler can be soot blower separately or both boilers can be blower in serial.
1001854 / 0D / Page 90 of 93
Kongsberg Maritime AS
Flowchart for No.1 or No.2 boiler sequence Start
Condition for next step - Steam Vlv Opened
- Other Boiler Drain Valve Closed
Start Start Permissive Terminate
Open Steam Vlv Timeout : 40 sec
Error
Close Other Boiler Drain Valve Timeout : 10 sec
Error
Timer 180s
- Steam Press OK
Check Steam Press OK Timeout : 2 sec
Error
- R3 Seq Run OR - Bypass ON
Start R3 If not Bypass ON Timeout : 2 sec
Bypass
- R3 Seq Run for 18 sec OR - R3 Seq Not Run - R4 Seq Run OR - Bypass ON
- Start from Monitor(IAS).
Wait, R3 blowing Timeout : 60 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 %
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam s upply valve abnormal - Boiler Trip - AC440V Failure
Start R4 If not Bypass ON Timeout : 2 sec
Bypass
Wait, R4 blowing Timeout : 60 sec
Error
Start R5 If not Bypass ON Timeout : 2 sec
Bypass
Wait, R5 blowing Timeout : 60 sec
Error
- R6 Seq Run OR - Bypass ON
Start R6 If not Bypass ON Timeout : 310 sec
Bypass
- R6 Seq Not Run
Wait, R6 blowing Timeout : 60 sec
Error
- Terminate all soot blower sub sequences
Close Steam Valve & Open Drain Vlv 1 & 2 Timeout : 10 sec
Error
- Open No1 MB Drain Vlv
- 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
- Close steam Vlv - Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
OR
Action
- Open No2 MB Drain Vlv - Set Alarm End
1001854 / 0D / Page 91 of 93
&
OR
Kongsberg Maritime AS
Flowchart for both boiler sequence Start
Condition for next step - Steam Vlv Opened
- No.2 Blr Drain Valve Closed
Start Start Permissive Terminate
Open Steam Vlv Timeout : 40 sec Close No.2 Blr Drain Valve Timeout : 10 sec
Error
Error
Check Steam Pressure OK Timeout : 2 sec
Error
No1 Boiler Blower Sequence R3,R4,R5,R6
- No.2 Blr Drain Valve Opened
Open No.2 Boiler Drain Vlv 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 %
- Emergency Retract ON - Steam press low & 30 sec after steam valve open - Steam s upply valve abnormal - Boiler Trip - AC 440V Failure
Timer 180s
- Steam Press OK
Check Steam Pressure OK Timeout : 2 sec
Error
No2 Boiler Blower Sequence R3,R4,R5,R6 - Steam Vlv Closed & - No1 MB Drain Vlv Opened & - No2 MB Drain Vlv Opened
OR
Action
Timer 180s
- Steam Press OK
- Start from Monitor(IAS)
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
1001854 / 0D / Page 92 of 93
&
OR
Kongsberg Maritime AS
9 ATTACHMENTS - Parameter List. (will be issued later) - ABC Operator Manual. (will be issued later)
1001854 / 0D / Page 93 of 93