Control & Automation

For
Super Critical Units

K.S. Sundaram
NTPC, SIPAT
1
Introduction
• Requirements
• Comparison of Auto loops -Sub Critical Vs Super Critical
• Feed Water Control
• Steam Temperature Control
• Unit Control
• Turbine Control
• Discussions

2
Super Critical Units
• Increased requirement of accuracy and resolution of DDCMIS
systems.
• No drum, hence no energy reserve.
• Need to match fuel ,air and feed water accurately.
• Stringent requirement of temperature controls as unbalance in
fuel and feed water has significant change in temperatures.
• Smooth changeovers between wet to dry operation and vice
versa
• Control system should ensure smooth steady state operation.
• Little need for operator intervention.

3
 4
Source :KEPRI
 5
Source :KEPRI
 6
Source :KEPRI
Comparsion Of Major Loops
Name of the loop Remarks SIPAT 660 MW
Furnace Draft No major difference Blade pitch control, Hydraulic

Air flow control No major difference Blade pitch control, Hydraulic

PA Hdr. control No major difference Blade pitch control, Hydraulic

Fuel master Cross limiting from FW VFD in feeders

FW control Saturation Temp Controller TDBFP 2 X 65%,
MDBFP 2X30%
SH temp control FW plays a major role FW plays a major role (Trip at
Temp >565 Deg)
RH temp control No major difference . Two tilts per corner (Trip at
Spray Should be Zero Temp>580 Deg)

7
List Of Loops For Discussion
S.N. Name of the loop Sub loops
01 Feed Water control Feed Water Master
BCP / UG valve
FWPCV control
Separator Drains control
02 Super heater temp Platen SH temp control
control SH steam temp control
03 RH steam temp Burner tilt control
control Spray valves control

8
Feed Water Control Requirements

• Ensure feed water flow in relation to unit demand.

• Adjust feed water flow to get the desired separator outlet
temperature and degree of super heat.
• Ensure the rangeability of platen SH spray valves
• Incorporate the start up level demand.
• Ensure minimum required feed water flow.
• Convert the flow requirement into pump demand with
compensation for pump capacities.
• Ensure protection for Fuel /FW ratio.
• Ensure the pumps are within the operating range.

9
Final Control Elements In FW Loop
Control Element Initial Condition Till Condition From BC
Chemical Parameter Is Pump Start / BLU Load > 30 %
Achieved Before Up To Load < 30 % DRY MODE
BC Pump Start WET MODE
MDBFP FW master in manual Separator Feed water flow
SCOOP/TDBFP control. Initial FW flow Level control control
Speed at 200 T/Hr and
Later 600T/Hr when
WR opens to 30%
BC Pump Feed water flow
Discharge Valve -- control --
Feed water FW pressure control at FW pressure Full open and
Valve ( Eq. to upstream of valve control at bypass valve opens
30% Valve ) upstream of valve
Separator Drain Separator Separator Hi
Valves WR/ZR Level control Level
--

10
Feed Water Master In Wet Mode
SEPARATOR ACTUAL LEVEL
LEVEL SET
POINT FROM
ULD SEPARATOR LEVEL SETPOINT
SUB
10

LEVEL SETPOINT
8

6
Series1
PID 4

2
0
0 100 200 300 400
ULD

ULD 0 300
TO BFPS
SP 9 3

11
Min FW Flow Control In Wet Mode
MIN. FW FLOW FW FLOW TO
SET POINT ECONOMISER

SUB
DP ACROSS BC DP SET POINT
PUMP ACROSS BC
PUMP
PID
SUB

PID
<
BC PUMP WILL TRIP IF DP
UG VALVE IS < 4.5 Kg/Sqcm

12
FWPCV Valve Control In Wet Mode
BFP HEADER
PRESSURE
TRANSMITTERS
SEL
HIGHEST OF TDBFP HIGHEST OF MDBFP
SUCTION FLOWS SUCTION FLOWS

SUB
FG FG

PID >

FWPCV
13
Separator Drains Control
MEASURED SEPERATOR LEVEL

F(X) F(X)

ZR
WR 14
 Wet Mode Operation
• Separator level control by BFPs and FW flow control by UG .Min FW
flow set point from boiler desk. Initial level set point is 9 Mtr. WR and
ZR will act as emergency control for separator level
• If water disappears in separator during wet mode then boiler will trip
on separator level low low – 1.1 Mtr (3 Sec delay)
• Boiler will trip if separator outlet level goes high high in wet mode –
17.7 Mtr
• WR opens at 14.2 Mtr in auto
• ZR opens at 16.2 Mtr in auto

15
Wet Mode & Dry Mode Of Operation

Source: Doosan 16
Feed Water Control In Dry Mode
• First controller acts on load dependant average DT across PDSH.
Its output represents the required adjustment to maintain the steam
conditions, flue gas temperatures entering Platen SH so as to
ensure adequate spray platen range.

• Second controller acts on load dependant separator temperature

set point corrected by first controller. The output adjusts feed water
in response to firing system disturbances.

• Minimum set point of 30% for safety is additionally provided.

17
 FW Master In DRY Mode PLATEN SH DT
SEPERATOR
OUT STM TEMP
BMD BOILER MASTER
DEMAND DSH SEP

SEPERATOR OUTLET F2(x)

TEMP SET POINT
F1(x)

NOT DRY MODE

SET TO ZERO
PI
FG ∑

PI

FF SIGNAL
∑
ANY SCANNER FLAME
0% (AND) BCP OFF

A
a 30 %
b
TOTAL FW FLOW
> T2 A

FB SIGNAL
FWF F(x)

PI

Source : KEPRI 18
TO BFPs
Platen DSH DT Set Point
BM(%) DT
DT SETPOINT IN FW LOOP 0 0
30 28.8 11
25
43.3 28
DT SETPOINT

20
15 Series1 52.1 22
10
70.7 9
5
0 91 9
0 50 100
100 11
BOILER MASTER

19
Source : EMERSON
Source : EMERSON
Source : EMERSON

22
 Runbacks /Rundowns/Protections
Runbacks /Rundowns

• Two TDBFPs – 120%

• One TDBFP + One MDBFP – 95%
• One TDBFP – 65%
• One MDBFP – 30%
• Rundown if FW deviation is high
• BFPS will go for pressure control when FW deviation is very high
• ID / FD / PA runback demand is 396 MW and turbine trip is 330 MW

Protections

• Feed water flow low low for 10 sec ( 440 T/Hr)

• Vertical wall tube metal temperature Hi Hi (4/48) (479 Deg)
• MS / RH STEAM temperature Hi Hi 565/580 Deg
• All BFP off for 20 Sec


23
Platen SH Temperature Control
• DT across PDSH is taken care by Feed water control.

• DT across FDSH and Load dependant DT SP acts on master

with over/ under firing FF which is derived from comparing rate of
change of fuel flow to rate of change of steam flow.

• Master output goes to slave via SP correction from steam flow

where input is PDSH outlet with saturation temp limitation.

• Incase of start up only master controller will be in service.

24
Final DSH DT Set Point
BM(%) DT
DT SETPOINT FOR FDSH
0 0
30 28.8 27
25
DT SETPOINT

20 43.3 21
15 Series1 52.1 18
10
5 70.7 7
0
91 7
0 50 100
BOILER MASTER 100 7

25
SH Temperature Profile

DIV SH PLATEN SH FINAL SH

406 451 440 486 480 540

DSH1 DSH2

15% 3%

26
Source : KEPRI 27
 Final SH Temperature Control

• DT across FDSH is taken care by Platen SH temperature control.

• Final SH O/L temp and Load dependant temp SP acts on master

with over/under firing FF which is derived from comparing rate of
change of fuel flow to rate of change of steam flow.

• Master output goes to slave via SP correction from steam flow

where input is FDSH outlet with saturation temp limitation.

• Incase of start up only master controller will be in service.

28
Source : KEPRI 29
RH Temperature Control (Tilt)

RH O/L AVG temp and temp SP (568 DEG) with

RHDSH DT correction (Max 5 DEG) correction fed to
PID, PID output with airflow FF goes to 2 sets of tilt - one
for wind box and other for SOFA

30
Source : KEPRI 31
RH Temperature Control By Spray
• RH O/L temp and load dependant temp. SP acts on master
controller.

• Master controller output is corrected with over/ under firing FF

which is derived from comparing rate of change of fuel flow to rate
of change of steam flow.

• Master O/P goes to slave via SP correction from steam flow where
input is RHDSH outlet with saturation temp. limitation.

32
Source : KEPRI 33
 34
Source :KEPRI
Source : EMERSON
Source : EMERSON
Turbine Control

• Speed Loop- Till synchronization (IP Rolling)

• IP is Throttle governing & HP is Nozzle governing
• Open load loop till HP is charged
• Pressure Control when HP is charged
• Sliding Pressure Operation from 90 to 247 Kg/sqcm
• Achieve full load & put on CMC

Salient Features:
• Individual EHC for individual valves
• No Hydraulic back up operation

37
HP BP Control

38
LPBP Control

39
 References

• KEPRI logics

• EMERSON Logics

40
THANK YOU
41
 FEED WATER PATH INITIAL STAGE Back

VERTICAL WW
SEPARATORS
F
W
R
STORAGE TANK S
ECONOMISER

ECO I/L
HPH

F
L
A
W S ZR
R H
T
A
N
K CONDE
NSER CEP LPH DA 42
 FEED WATER PATH - LOAD < 30% Back

VERTICAL WW
SEPARATORS
S
T
O
R HPH
A
G
E

T ECONOMISER
A
N
K
ECO I/L

MIXING PIECE

BCP UG

43
 Back
FEED WATER PATH – LOAD > 30%

S S
E E
P P VERTICAL WW
A A
R R
A A HPH
T T
O O
R R
ECONOMISER

ECO I/L

TO BACKPASS
CONNECTING PIPES

44
45
CCP Auto Start And Auto Stop Conditions

Source :Doosan 46