Bharat Heavy Elelctricals Limited: Operation & Maintenance Manual of Bhelscan Flame Scanner System (Bn10)
Bharat Heavy Elelctricals Limited: Operation & Maintenance Manual of Bhelscan Flame Scanner System (Bn10)
Bharat Heavy Elelctricals Limited: Operation & Maintenance Manual of Bhelscan Flame Scanner System (Bn10)
BHARAT HEAVY ELELCTRICALS LIMITED, HIGH PRESSURE BOILER PLANT (Controls and Instrumentation / Fossil Boilers), Tiruchirappalli - 620 014, INDIA
Phone: 91 (0431) 257 5218, 257 5027
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CONTENTS
Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 6.1 Section 6.2 Section 6.3 Section 6.4 Section 7 Section 8 Section 8.1 Section 8.2 Section 8.3 Section 8.4 Section 8.5 Section 8.6 Section 9 Section10 Section 10.1 Section 10.2 Section 10.3 Section 11
INTRODUCTION SYSTEM SPECIFICATION MECHANICAL COMPONENTS COOLING AIR REQUIREMENTS ELECTRICAL COMPONENTS DESCRIPTION OF MODULES FLAME PROCESSOR MODULE 2/4 OUTPUT MODULE POWER SUPPLY MODULE SCANNER HEAD ELECTRONICS COMMUNICATION INTERFACE INSTALLATION AND START UP PROCEDURES MECHANICAL COMPONENTS COOLING AIR ELECTRICAL COMPONENTS SYSTEM OPERATION TEST DIP SWITCH SETTING PROCEDURES CALIBRATION OF SCANNER HEAD ELECTRONICS FLAME SCANNER CABLE MAINTENANCE & TROUBLESHOOTING SCANNER HEAD FIBRE OPTIC CABLE ELECTRICAL COMPONENTS LIST OF FIGURES
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LIST OF FIGURES:
Figure-1 Figure-2 Figure-3 Figure-4 Figure-5 : Windbox arrangement showing Flame scanner system : Flame Scanner Guide pipe assembly : Flame scanner assembly with optical head : Collimeter lens with barrel assembly : Functional block diagram
Figure-6A : BHELSCAN - General arrangement Figure-6B : BHELSCAN - General arrangement Figure-6C : Schematic of processor motherboard Figure-7A : Block diagram of Flame processor Figure-7B : BHELSCAN Flame processor module Figure-8A : Block diagram of 2/4 output module Figure-8B : BHELSCAN 2/4 module Figure-9A : Block diagram of power supply Figure-9B : BHELSCAN Power supply module (Front view) Figure-9C : BHELSCAN Power supply module (Rear view) Figure-9D : Schematic of power supply motherboard Figure-10 : Block diagram of Scanner Head electronic module Figure-11A : Flame scanner interconnection diagram Figure-11B : TB wiring details (Front mounted TB version) Figure-11C : TB wiring details (Rear mounted TB version) Figure-11D : BHELSCAN TB arrangement (Rear mounting)
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Section 1 INTRODUCTION
The prime output of flame sensing The microcontroller based flame sensing system is designed primarily for use on coal fireball and stable oil flame ignited by high energy arc (HEA) ignitor. It senses the visible light given off by the flame and can recognize a coal/oil flame by its characteristic fluctuations. The system consists of a fibre-optic connected scanner head assembly and a chassis containing electronic signal processing modules. The scanner head system is called the two out of four flame ON for coal, when two or more than two coal flame in an elevation is detected and individual flame ON for oil. The output is represented by the positioning of a set of form C contacts (break before make). A current signal is also available to indicate the individual flame intensity corresponding to each corner. RS232C serial output is available for computer/DCS connectivity.
assy. is located at the boiler and the chassis with electronics is mounted in the control room. The chassis may be located up to 200 metre from the boiler. A shielded four-conductor cable sends power to the scanner head electronics and returns an electronic signal representing flame to the chassis. The scanner head assy. is normally installed wind in the wind box assembly to (Figure-1). Refer to the respective project box arrangement drawing determine the location of scanner head assy. in the system.
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2/4 Processor : 2/4 logic detection & fault Programmable : Pull in, Pull out, Parameters Display Display mode selection Parameter setting Communication : Serial interface Enclosure : 19 Rack with 3U size cards : 4 x 8 bit DIP switch Flicker frequency for oil, Flicker frequency for coal : 2 digit LED display : By Push button
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The complete mechanical assembly is comprised of a stationary part, called the flame scanner guide pipe assembly and a removable part, called the flame scanner assembly.
COMPRESSED ZERO
TO
ITS TILT.
MINIMUM IF A
LENGTH WHEN THE WIND BOX IS AT (HORIZONTAL) GUIDE SCANNER PIPE IS FIELD-
INSTALLED, BE SURE IT IS MOUNTED IN THE SAME MANNER TO PREVENT DAMAGE TO THE FLEXIBLE HOSE AND CONNECTIONS WHEN THE NOZZLE IS TILTED THROUGH ITS RANGE. ANY RADIUS OF CURVATURE GREATER
THAN 18-IN MAY BE UTILIZED AS LONG AS ITS CROSS SECTION IS CIRCULAR AND DOES NOT RESTRICT FREE MOVEMENT OF THE SCANNER HEAD WITHIN THE CURVED PORTION. The guide pipe is normally fixed in the wind box front by means of a packing gland. The cooling air manifold is screwed (NPT) onto the guide pipe. The cooling air manifold is drilled and tapped to accept a flexible hose connection at its cooling air inlet and has an opening for the flame scanner head assembly. The scanner opening must be closed with the cover plate when the assembly is removed for maintenance.
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reason to disassemble the scanner head assembly, except to clean the collimator shield (see the Maintenance and Trouble shooting section of this manual). The scanner housing couples the flame scanner assembly to the guide pipe and signal. A weatherproof disconnect coupling is provided to conveniently connect external wiring. A hexagon adapter adapts the connector to a in. pipe thread. Sealtite flexible hose or a similar weatherproof conduit should be used between the disconnect coupling and the rigid conduit leading from the wind box assembly. The flame scanner head assembly can be assembled in the following manner : 1. Slip fit the collimator tube and shield assembly into the scanner head body and hold it in place with a single Allen head screw. Using spacers, position the shield on the collimator to a allow cooling air to flow through the head assembly. (Figure 4). contains the the electronics for conditioning fibre-optic-transmitted
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NOTE A wind box structure will sometimes restrict the location of the guide pipe scanner head housing. To permit the 4. scanner to see the flame, a prism may be installed in place of the collimator shield. Use care when placing the 5. scanner in the guide pipe to assure proper orientation of the scanner head assembly. 2. Thread the fibre-optic cable, which is normally coiled inside the scanner housing assembly, through the rigid pipe, flex metal hose and the scanner head body plug. Make sure the jam nut is in place on the cable before installing the compression spring and mounting plate. Then screw the collimating lens barrel onto the cable. 3. Lock the mounting plate to the lens barrel with the jam nut. Insert the lens barrel in the scanner head body until the mounting plate rests against the stop pins. Insert the compression spring and plug. Three socket head screws hold the plug in the scanner head body.
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output signal is an AC current signal, which is sent to the card rack assembly for processing. Refer functional block diagram. ( Figure 5 ) In the card rack assembly, each current flame signal is converted into a voltage flame signal. The voltage flame The intensity signal is then separated into intensity and frequency components. component of the signal varies between no flame value (dark furnace) and a normal flame value based on the actual flame intensity. The frequency component of the signal is used to prove that an active flame exists. a) An intensity signal indicates the magnitude of the flame brightness. A 2 digit LED display in the front facia of flame scanner module
adjusted limits (pull in, pull out settings), an intensity light will come ON at the associated scanner channel. A flame signal will be established only if no fault (fault LED is OFF) signal exists and a predetermined component (frequency setting) is proven to exist. The frequency of the fire ball (coal flame) is normally lower than the frequency of the individual oil gun flame. Therefore, when at least 2 out of 4 scanner channels show coal flame, the system 2/4 flame light will come ON in the front facial of 2/4 module. If any scanner channel indicates a fault, the associated scanner channel fault LED frequency F1, F2
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will come along with the system fault LED and that channels flame output will be disabled. The 2/4 module gives 2 changeover contacts for 2/4 flame and one
changeover contact output for system fault. Description of the various modules are given in the following sections:
Refer
monitoring circuit. This consists of a voltage amplifier and an ADC. The output of this ADC is connected to Microcontroller.
flame condition independently for coal and oil flame flicker levels by RP1 and RP6 single turn potentiometers respectively.
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located at furnace front in the field from this module. There are two semiconductor fuses rated for 63mA are available in the flame processor motherboard to protect the DC supply to scanner head electronics. The removal of this module blocks the DC supply to field. DO NOT REMOVE ANY MODULE WITH POWER ON There are 4 DIP switches (each switch with 8 bits) are available to set the following data in binary form to the microcontroller. For DIP switch settings, refer DIP SWITCH SETTING PROCEDURE. a. Pull in value (typical value is 40%) b. Pull out value (typical value is 30%) c. Coal d. Oil frequency frequency set set value value (typical value is 5 Hz. ) (typical value is 30 Hz. ) - Adjustable at site. The front facia of this module consists of a 7-segment display, 9 status LEDs and one Push Button. Card pullers are available to remove the card from the rack. A mode PB can change the display mode to scroll the various values. The heart of the system is an 8-bit microcontroller. This receives the signals from ADC, wave shaping circuit, mode PB and DIPswitches. From these signals, the microcontroller decides the flame status
and energies the relay. Also, the status of flame1 and flame 2 and fault are transferred to the 2/4 output module. The microcontroller updates the display and LED status according to the input. The digital outputs of flame1 (coal) and flame2 (oil) status are fed to the 2/4 output module. A 4-20 mA current output is available to represents the intensity of the flame. This circuit consists of a DAC and current converter. Relay outputs are available in form of change over contact for flame 2(oil) output to use in BMS of boiler. For the location of DIP switches and AC gain potentiometers, refer Figure - 7B.
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are two relays available. One relay is for the 2/4 output of coal flame. The other relay is for fault alarm to DCS. RS232C serial communication circuit, transfer the flame parameters for all processor modules to computer on-line via serial port. Two sets of 2/4 output relay contacts are available at the terminal. These are changeover contacts. In the front facia, two status LEDs are available for 2/4 output indication and fault status. Refer Figure 8B for the location of 2/4 relay (Fireball flame ) and fault relay.
power supply motherboard to switch ON the AC power supply to this module. In the front facia, four status LEDs are available for presence of AC power ON, -15V DC ON, +15V DC ON and +5 V DC ON. All four LEDs should glow for the normal operation of flame scanner.
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through potentiometers R101, R103. This voltage signal is converted to current signal (0 2.0 mA) for transmission to flame processor module. A feedback LED is mounted in the photo diode holder, to avoid the saturation of log amplifier in the event of very low light
or dark furnace conditions. This feedback loop is the key circuit in the electronic fault detection scheme. The light emitted by the feedback LED is adjusted by R114 at potentiometer during calibration
laboratory / factory.
output is provided in each BHELSCAN covering four corners of one elevation. Terminal block (TB5) in system mother board has 3 terminals viz. 10, 11, 12 for Transmit (Tx), Receive (Rx) and ground. Prepare a cable (2 pair twisted 0.5 Sq.mm shielded cable) with one side soldered to 9 pin D type connector suitable for inserting into COM1 or COM2 serial port of personal computer and connect the other side to these terminals. The 2/4 output module periodically interrupts each flame scanner and collect the following data. This data will be communicated via serial output approximately once in a second.
To select COM1 or COM2 (Enter 1 or 2) = Now enter the COM port Number 1 or 2 in which the communication cable is connected. Communication will be established and PC will display the following corresponding to 4 corners.
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FLAME SCANNER CORNER1 Actual Intensity Pull in set Pull out set Frequency 1 set Frequency 2 set Actual frequency 1 Actual frequency 2 Flame 1 Flame 2 The above table will be updated automatically every second approximately. CORNER2 CORNER3 CORNER4
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On balanced draft units, the cooling air for the scanners is frequently supplied by a separate fan and piped to the scanner cooling air manifolds. The scanner cooling air supply is taken from the forced draft (FD) fan discharge duct in combination with combustion air to the ignitors. In this case an emergency damper, a low air pressure switch, a high air pressure switch and a scanner fan are also provided. The scanner fan starts when the air pressure gets too low, usually at 6 in. w.g.
Power supply mother board Most air systems are supplied with air filters between the scanner fan and the cooling air manifold. A differential pressure gauges and switches to actuate an alarm are installed across the filter to provide information on filter condition. should be checked cleanliness. The emergency damper opens to admit ambient air to the system when the FD fans are out of service. All components should be checked for proper operation. Filters for TBP1 TBP1 2 3 periodically TB No. TBP1 Terminal DESCRIPTION No. 1 Phase (230V or 110V as given in the name plate) Neutral Earth
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Processor mother board TB No. TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB1 Corner 1 TB2 - Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB2 Corner 2 TB3- Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 Terminal No. 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common Flame-2 relay contact NC Current output negative Current output positive +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common Flame-2 relay contact NC Current output positive Current output negative +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common B+ BSIG GND Sh. NO COM NC II+ B+ BSIG GND Sh. NO COM NC II+ B+ BSIG GND Sh. NO COM DESCRIPTION MARKING
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TB3 Corner 3 TB3 Corner 3 TB3 Corner 3 TB4 - Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB4 Corner 4 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5 TB5
8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12
Flame-2 relay contact NC Current output positive Current output negative +15V to Head Electronics -15V to Head Electronics Signal from Head Electronics Signal ground from Head Electronics Power supply shield & overall shield Flame-2 relay contact - NO Flame-2 relay contact common Flame-2 relay contact NC Current output positive Current output negative 2/4 flame contact NO 2/4 flame contact common 2/4 flame contact NC 2/4 flame contact NO 2/4 flame contact common 2/4 flame contact NC selectable System fault contact common No connection Transmit Receive Ground
NC II+ B+ BSIG GND Sh. NO COM NC II+ NO1 COM1 NC1 NO2 COM2 NC2
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6. Whenever the power is switched ON, the display will show the intensity. The corresponding IN LED will glow. 7. The display mode can be changed by momentarily pressing and releasing the MODE PB (square PB). 8. The following display modes are available. 1. IN intensity 2. PI-Pull in set value of intensity 3. PO-Pull out set value of intensity 4. F1- coal frequency set value 5. F2-oil frequency set value 6. AF & F1- actual frequency of coal 7. AF & F2- actual frequency of oil 9. Select PI mode. The display should read the pull-in set value in %. Similarly, change the modes and verify the other values as shown from 8.2 to 8.5 above. 10. Press mode PB again momentarily. Now, LEDs corresponding to AF and F1 both will glow simultaneously. The display reads the actual coal frequency (F1). 11. Press mode PB again momentarily. Now, LEDs corresponding to AF and F2 both will glow simultaneously. The display reads the actual oil frequency (F2). 12. To change the set values of IN, PI, PO, F1 and F2 if needed, refer parameter setting procedures given above.
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13.
During boiler operation, the Flame1 LED in respective corner processor module will be ON when the following conditions are met.
e. f.
Oil frequency is less than F2 set value OR Any fault conditions exits. (Fault LED ON)
a. b. c.
Flame intensity is more than PI set value AND Coal frequency is more than F1 set value AND No Fault condition exists (Fault LED OFF) Flame1 LED will switch OFF, if any one of the following conditions is met.
15. 4-20 mA current output is available corresponding to 0 100% of flame intensity in respective corner at TB Nos. 9 & 10. If any fault condition exists, (Fault LED ON), this current output will go to 4 mA irrespective of the intensity level shown in display. 16. The 2/4 Flame LED indication in 2/4 flame module represents the presence of fireball during coal firing. This LED will be ON, whenever, two or more corners Flame1 (coal flame) show flame. The relay outputs in two sets of contacts are available at TB Nos.1,2&3 and 4,5 & 6 of TB5. 17. If any fault LED is ON in any of the processor modules, Fault LED in 2/4 module will be ON. The Fault relay will get energized. The relay output is available in TB Nos. 7&8 of TB5. 18. RS232-C serial communication output is available at TB Nos.10, 11 & 12 in TB5. This can be used to communicate the flame parameters to Personal Computer.
a. b. c. 14.
Flame intensity is less than PO set value OR Coal frequency is less than F1 set value OR Any fault conditions exits. (Fault LED ON) During boiler operation with oil, the Flame2 LED will be ON when the following conditions are met. The relay output is available at TB Nos. 6,7 & 8 in the respective corner.
a. b. c.
Flame intensity is more than PI set value AND Oil frequency is more than F2 set value AND No fault condition exists. (Fault LED OFF) Flame2 LED will switch OFF, if any one of the following conditions is met.
d.
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Locate S2 DIP switch as shown in Figure 7B for intensity pull-out value. Set 30 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF 5 ON 4 ON 3 ON 2 ON 1 OFF
Locate S3 DIP switch as shown in Figure 7B for coal frequency set value. Set 05 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF 5 OFF 4 3 2 OFF 1 ON OFF ON
Locate S4 DIP switch as shown in Figure 7B for oil frequency set value. Set 30 by keeping the individual switch as below. DIP switch position: Setting status 8 OFF 7 OFF 6 OFF 5 ON 4 ON 3 ON 2 ON 1 OFF
For other values of above settings, convert the decimal value to 8 bit binary and set the DIP switches accordingly. For 1 status, the switch shall be in ON position. Repeat the same procedure for settings in other flame processor modules. Insert the modules into the respective location and switch ON the AC power supply. Verify the set values in individual flame processor module by selecting the display using mode PB.
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22
of
Scanner
(DVM) between signal C and common D terminals on the electronics card; then reconnect the scanner cable. Turn the scanner power supply on and adjust potentiometer R101 to provide a reading of 0.000 V on the DVM. Replace the 1 mA dc current source with a 1 A source and adjust potentiometer R103 to provide a reading of 1.000 V on
The scanner head electronics are adjusted during manufacturing. If a component on the electronics card is replaced, field adjustment be required. of the gain and offset potentiometers and dark furnace bias will
of
Scanner
the DVM.
and test leads, reconnect the photodiode and proceed with the dark furnace bias adjustment.
Furnace
Bias
operation
of
the
BHELSCAN relatively uniform voltages must be input to the chassis by the four associated scanner assemblies during dark furnace, no fire conditions. Total absence of a signal from the scanner assembly would generate a fault condition. To prevent this from occurring, feedback LED is installed on the scanner head electronics card adjacent to photodiode. The flame scanner assembly should be removed from its guide pipe and the scanner cover plate should be installed. Completely block all light from the furnace end of the fibre-optic cable and open the scanner housing.
Disconnect
Simulate a
photodiode input by connecting the 1 mA dc current source to the photodiode terminals. Connect the digital volt meter
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Connect a digital voltmeter (DVM) between the signal C and common D terminals on the electronics card. Reconnect the scanner cable to the scanner assembly. The power supply switch should be turned on. Work under a dark cloth to reduce he amount of ambient light admitted to the scanner head. Adjust potentiometer P114 so that the DVM reads
electronics
Disconnect the test leads, reassemble the scanner assembly and reinsert it in the guide pipe. All four scanner channels, under dark furnace conditions, should have a similar intensity meter reading.
Insulated, Twisted pair, Aluminium Backed Mylar Tape Shielded with Drain Wire, 2 such pairs laid up, Over all Aluminium Backed Mylar Tape Shielded with Drain Wire, Sheathed Cable. Elastomeric / Thermoplastic/Equivalent material Over all
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periodically and cleaned, if necessary. Hence, an inspection program should be established experience. based on operating
depend on the type of fuel used, the plant cleanliness of the cooling air.
operating
experience. Always check the shield and lens when the scanner head is inspected.
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flame scanner cable connection between the terminal block and the head electronics in the field. If continuity is
vanish.
2/4 flame module may need replacement. Do not insert or pull out any module from the connector when power is ON. This may damage the module. If any module has to be removed for examination or changing the settings, it is safe to switch OFF the power by operating the toggle switch SO1 in the power supply mother board and wait till all the lamps in the power supply module go OFF. Then remove or insert the module and then switch ON the toggle switch SO1 if needed to power up the system.
also alright, then head electronics may need recalibration or replacement. response for mode selection For PB, any other fault in this module like no improper display, etc., the module is to be replaced. In 2/4 flame module, the fault lamp should be OFF for normal operation. If the fault lamp is ON, then fault lamp in any one or more of the flame processor modules may be ON. If that module is attended, this fault may
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