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Title Page BURNER MANAGEMENT and COMBUSTION CONTROL SYSTEM
Periodic Safety Test Procedure
TS KENNEDY
DOCUMENT NUMBER:
TSK 800-03
REV - 7
DATED: 01/07/2018
Manufactured by:
Instruments and Controls, Inc.
Westminster, MD 21157 Table of Contents
| Title Page | 1 |
| Table of Contents | 2 |
| Revisions | 3 |
| General Information and Instructions | 4 |
| System Alarms and Indicators | 5 |
| Boiler Control and Safety System | 5 |
| Windbox Purge Cycle | 5 |
| Trial for Ignition: Flame Failure | 6 |
| Open manual supply valve to the burner | 6 |
| Proving atomizing steam/atomizing air flow to the burner | 6 |
| Drum Water Level Trip | 7 |
| High Steam Pressure Trip | 7 |
| Low Fuel Oil Pressure Trip | 8 |
| Low Atomizing Steam Pressure at the Header Trip | 8 |
| Low Combustion Air Flow Trip | 9 |
| Emergency Boiler Trip [Manual] | 10 |
| Verify Operation of Final Control Element Yokogawa Controllers | 10 |
| Verify PLC Failure Alarm | 11 |
| Verify Fuel Selection | 11 |
Revisions
| Revision |
| Date |
| Description |
| --- |
| 12/22/2011 |
| Initial issue. |
| 1 |
| 12/27/2011 |
| Updated from comments from USCG MSC |
| 2 |
| 01/03/2012 |
| Updated post-testing to reflect comments from OCMI |
| 3 |
| 01/07/2103 |
| Updated post-testing to reflect comments from OCMI |
| 4 |
| 01/09/2013 |
| Updated post-testing to reflect comments from OCMI |
| 5 |
| 01/02/2015 |
| Updated post-testing to reflect comments from OCMI |
| 6 |
| 11/28/2017 |
| Edited to include USCG comments on letter E2-1703605 of 09/25/2017. Added fuel selection to required testing. |
| 01/07/2018 |
| Addressed comments in USCG Letter E2-1704764 of 12/28/2017 |
Removed requirement for HFO Temperature as a permissive: The HFO Temp sensor is not on the HFO Fuel Header; it is on the Boiler front and is a requirement for boiler light off operation only.
General Information and Instructions
1. The test procedure described herein is intended as a guide for use by ABS and/or USCG inspectors during periodic inspections.
This section applies only to the inspection of the vital system, alarms, and safety devices. The test procedures described herein are to be followed by the Officer-in –Charge, Marine Inspections when conducting inspections for certification and mid-period inspections.
2. This Burner Management System (BMS) provides alarm indications on the Port and Starboard BMS Panels located in front of each boiler on the inboard side. The BMS provides an audible and visual alarm upon activation of any alarm or system trip condition. These indications will continue to flash when actuated until acknowledged, at which time they will cease and remain on continuously. Once acknowledged, the indicator will remain continuously illuminated until the alarm or trip condition is return to “normal”.
3. Please note that during the entire test outlined, the operation of the equipment shall be under the control of Licensed Engineer at all times.
4. The following procedures are to be adhered to during testing of all indicated alarms.
A. Pressure: The use of the system pressures is the desired method of testing. When these methods are impractical, adjusting the setpoint beyond the actual process variable is an acceptable alternative.
B. Temperature: Remove field device and put into an adjustable temperature source. Adjust to temperature indicated or input an acceptable simulated source. When these methods are impractical, adjusting the setpoint beyond the actual process variable is an acceptable alternative.
5. Test equipment if required:
A. Variable temperature source B. Hand held pressure pump C. 4-20 mA simulator
6. Note that all tests indicating fuel valve operations will apply to the valves associated with the selected fuel type (HFO or LSGMO)
Item No.
| Description |
| PORT Verified STARBOARD |
| Port Lower Burner |
| Port Upper Burner |
| Starboard Lower Burner |
| Starboard Upper Burner |
1.
System Alarms and Indicators
Verify the following alarm indications. Verify alarm response of each according to information provided in item 2 of the 'General Information' section.
1.
Forced Draft Fan Failure (Loss of Air) Trip
2.
Flame Failure Trip
3.
Drum Level Low-Low Trip
4.
Atomizing Steam Header Pressure Low Trip
5.
Fuel Oil Pressure Low Trip (30 psi)
6.
Steam Pressure High Trip (Verify Boiler trips before Superheater Safety lifts)
7.
Emergency Boiler Trip
8.
Atomizing Steam Pressure at Burner Low Trip
9.
Fuel Oil Temperature Low (160 F)
10.
Drum Level Low
11.
Drum Level High
12.
Drum Pressure Low/High (500/600 psi)
2.
Boiler Control and Safety System
1.
Windbox Purge Cycle
With the BMS panel for test boiler switched to the “Remote” position, the main fuel valve will “open” and the “Boiler start” indicator will flash when all required interlocks and safeties are satisfied and reset. Press the “Boiler Start” push button.
| 1 |
| Verify the air registers for both burners are open. |
| 2 |
| Verify the forced draft fan damper opens |
| 3 |
| Verify that the “Purging “ indicator flashes until Damper opens to 60% as indicated on the Yokogawa combustion control air flow station, at which time the “Purging“ indicator will light continuously, indicating that the purge timer has started. |
| 4 |
| Verify the purge cycle time continues for 60 seconds. When the purge is complete the “Purging” lamp will extinguish and the “Low Fire Hold” lamp will illuminate. |
2.
| Trial for Ignition: Flame Failure |
| Note: Tests should be conducted for each fuel supply. |
| 1 |
| Manually close the fuel oil valve to Burner under test. Press the start push button for Burner to initiate the ignition cycle. |
| 2 |
| Verify the burner fuel oil valve solenoid energizes to open the valve. |
| 3 |
| Verify that after 15 seconds a 'Flame Failure' alarm is activated for the burner. |
| 4 |
| Verify the burner fuel oil valve (FOV) and the main FOV close. |
| 5 |
| Verify that the boiler cannot be restarted until reset (reset is done by pressing the BMS “Stop” pushbutton of the boiler being tested.) |
| 7 |
| Open manual supply valve to the burner |
3.
Proving atomizing steam/atomizing air flow to the burner
Note: An atomizing steam pressure switch is provided at each burner to prove proper steam flow to the burner prior to allowing ignition. The burner must be properly coupled before atomizing steam pressure switch can be made.
| 1 |
| Manually close the atomizing steam valve on Burner being tested and bleed off the trapped pressure. Observe alarm and acknowledge. |
| 2 |
| Verify the 'Burner Start' indicator extinguishes at the Main Control Panel. |
| 3 |
| Press the "burner start" pushbutton and verify that the ignition cycle is not initiated. |
| 4 |
| Open the valve for the burner atomizing steam pressure switch. |
4.
| Drum Water Level Trip |
| Verify for each fuel type selection |
| 1 |
| With boiler being tested in normal operating condition, begin dropping the drum water level. Acknowledge the LOW Level alarm and continue to decrease the level until the LOW-LOW alarm point is reached. |
| 2 |
| Verify that water is still visible in Drum Sight-Glass. |
| 3 |
| Verify that the 'Drum Level LOW-LOW' alarm activates. |
| 4 |
| Verify the 'Boiler Trip' alarm activates. |
| 5 |
| Verify that the main fuel valve closes. |
| 6 |
| Verify all fuel oil valves close. |
| 7 |
| Verify that the boiler cannot be restarted until the Drum Level LOW-LOW alarm has been cleared. |
| 8 |
| Acknowledge the alarms and begin raising the drum level to normal. |
5.
| High Steam Pressure Trip |
| Verify for each fuel type selection |
| 1 |
| While observing the Superheat Mimic on the AMS HMI, allow the steam pressure to increase until the high steam pressure alarm point is reached for the boiler being tested. |
| 2 |
| Verify that the 'High Steam Pressure' alarm activates at or below 600 psi. |
| 3 |
| Verify that the 'Boiler Trip' alarm activates before Superheater Safety lifts. |
| 4 |
| Verify that the main fuel valve closes. |
| 5 |
| Verify that all burner fuel oil valves close. |
| 6 |
| Verify that the boiler cannot be restarted until the High Steam Pressure alarm has been cleared. |
| 7 |
| Acknowledge the alarms and allow the steam pressure to drop to normal. |
| 8 |
| When the High Steam Pressure alarm has cleared, return the boiler to normal operation. |
| 9 |
| Repeat steps 1-8 for MGO fuel selection |
6.
| Low Fuel Oil Pressure Trip |
| Verify for each fuel type selection |
| 1 |
| With both burners in operation, utilizing the Main Fuel Oil Regulating Valve, lower the fuel oil pressure, on the boiler being tested, until the low alarm limit has been reached [30 psi as read on local gage] |
| 2 |
| Verify that the 'Low Fuel Oil Pressure' alarm activates after a 30 second time delay. |
| 3 |
| Verify that the 'Boiler Trip' alarm activates. |
| 4 |
| Verify that the main fuel valve closes. |
| 5 |
| Verify that all fuel oil valves close. |
| 6 |
| Verify that the boiler cannot be restarted until the Low Fuel Oil Pressure alarm has been cleared. |
| 7 |
| Acknowledge the alarms and return the fuel oil pressure to normal. |
| 8 |
| When the Low Fuel Oil Pressure alarm has cleared, return the boiler to normal operation. |
| 9 |
| Repeat steps 1-8 for MGO fuel selection |
7.
| Low Atomizing Steam Pressure at the Header Trip |
| Verify for each fuel type selection |
| 1 |
| Lower the atomizing steam pressure by slowly closing the main valve on the atomizing steam supply line, on the boiler being tested, until the low alarm limit has been reached. |
| 2 |
| Verify that the ‘Low Atomizing Steam Pressure' alarm activates at both burners and the header. |
| 3 |
| Verify that the 'Boiler Trip' alarm activates. |
| 4 |
| Verify that the main fuel oil valve closes. |
| 5 |
| Verify that all burner fuel oil valves close. |
| 6 |
| Verify that the boiler cannot be restarted until the Low Atomizing Steam Pressure alarm has been cleared. |
| 7 |
| Acknowledge the alarms and return the atomizing steam pressure to normal by opening the supply valve. |
| 8 |
| When the Low Atomizing Steam Pressure alarm has cleared, return the boiler to normal operation. |
8.
| Low Combustion Air Flow Trip |
| Verify for each fuel type selection |
| 1 |
| Stop the forced draft fan. |
| 2 |
| Verify that the 'Forced Draft Fan/Air Flow Low' alarm activates. |
| 3 |
| Verify that the 'Boiler Trip' alarm activates. |
| 4 |
| Verify that the main fuel valve closes. |
| 5 |
| Verify that all burner fuel oil valves close. |
| 6 |
| Verify that the boiler cannot be restarted until the Low Combustion Air Flow alarm has been cleared. |
| 7 |
| Acknowledge the alarms. |
| 8 |
| Restart the forced draft fan. When the Low Combustion Air Flow alarm has cleared, return the boiler to normal operation. |
| 9 |
| Disconnect the low side connection to the Combustion Air Flow, minimum air flow switch to the boiler being tested and remove the high side plug. |
| 10 |
| Verify that the 'Forced Draft Fan/Air Flow Low' alarm activates. |
| 11 |
| Verify that the 'Boiler Trip' alarm activates. |
| 12 |
| Verify that the main fuel valve closes. |
| 13 |
| Verify that all burner fuel oil valves close. |
| 14 |
| Verify that the boiler cannot be restarted until the Low Combustion Air Flow alarm has been cleared. |
| 15 |
| Acknowledge the alarms. |
| 16 |
| Restart the forced draft fan. When the Low Combustion Air Flow alarm has cleared, return the boiler to normal operation. |
9.
Flame Failure Trip
| 1 |
| Start the boiler being tested, and place a burner in operation. Close the manual valve at the burner front. Within 5 seconds after the flame has extinguished: |
| 2 |
| Verify the “Flame Failure” alarm activates for the burner being tested. |
| 3 |
| Verify that the burner FOV closes. |
| 4 |
| Acknowledge the alarms. |
| 5 |
| Verify that with both burners showing “Flame Failure”, the following actions will occur: |
| 6 |
| The “Boiler Trip” alarm activates. |
| 8 |
| Open the fuel valves for all burners and return the boiler to normal operation. |
NOTE: With ANY burner still operating, a Boiler Trip is not initiated.
10.
| Emergency Boiler Trip [Manual] |
| Verify for each fuel type selection |
| 1 |
| With the boiler operating, press the 'Emergency Trip' push button. |
| 2 |
| Verify that the 'Emergency Trip' and ‘Boiler Trip' alarms activate. |
| 3 |
| Verify that the main fuel valve closes. |
| 4 |
| Verify that all burner fuel oil valves close. |
| 5 |
| Acknowledge the alarms. |
NOTE: When any 'Boiler Trip' alarm is initiated, the boiler will not automatically restart. The control system must be manually reset to restart the boiler by pressing the 'Boiler Stop' pushbutton.
3.
Verify Operation of Final Control Element Yokogawa Controllers
| 1 |
| Test the following loops (open and close) |
| 2 |
| Fuel Oil Flow Control Valve |
| 5 |
| #1 Feed Pump Controller |
| 6 |
| #2 Feed Pump Controller |
| 7 |
| DC Heater Make Up Controller |
| 8 |
| DC Heater Dump Controller |
| 9 |
| Main Condenser Level Controller |
4.
Verify PLC Failure Alarm
1.
Open PLC Cabinet and open breaker.
| 2. |
| Verify that the main fuel valve closes. |
| 3. |
| Verify that all burner fuel oil valves close. |
| 4. |
| Verify that all lights on front of BMS Console extinguish. |
| 5. |
| Verify BMS Summary Alarm lights on Main Console and Audible Alarm Sounds. |
| 6. |
| Verify loss of all data for Boiler on HMI |
| 7. |
| Verify Alarm Message “Comm error or dynamic disable, device: AMOS : PBMS” on HMI. |
| 8. |
| Verify Alarm Message “Comm error or dynamic disable, device: AMOS : SBMS” on HMI. |
5.
Verify Fuel Selection
1.
| LSGMO Operation |
| Port Boiler |
| Stbd Boiler |
| 1. |
| Verify all permissives required for proper operation are satisfied as indicated in steps a. thru c. shown below: |
(Verify on the boiler mimic screen provided)
| a |
| Manually Open the fuel system valves as indicated. The icon indicating “Valves are aligned” when the proper alignment is done: |
1. Port Supply V01P and Return Valves V02P or
2. Stbd Supply V01S and Return Valves V02S
| b |
| Start either one of the fuel pumps and confirm it indicates running on the screen icon |
1. Port or
2. Stbd
| c |
| Insure the Fuel pressure at the header is adequate by observing the local gauge (min: 80 psig) and the icon on the screen |
| 2. |
| Press the LSGMO pushbutton at the BMS cabinet and confirm it illuminates |
2.
| HFO Operation |
| Port Boiler |
| Stbd Boiler |
| 1. |
| Verify all permissives required for proper operation are satisfied as indicated below: |
(Verify on the boiler mimic screen provided)
| a |
| Start the HFO fuel Pump and verify the Fuel pressure at the header is adequate (minimum: 65 psig) by observing the local gauge. The screen icon will indicate that pressure is OK. |
| 2. |
| Press the HFO pushbutton at the BMS cabinet and confirm it illuminates. |
TSK 800-03 Rev 7 – January, 2018 Page 1 of 12