Introduction to

Auto Control Loops in Thermal Power Plant

A presentation for NPTI, Neyveli

Sith.Ananda Kumar,
Assitant Executive Engineer, Thermal Power Station-II, Neyveli Lignite Corporation.

Automation
Preprogrammed execution

Less or no manual intervention

Time driven or event driven

Control loop
Auto / Manual Closed / Open Critical / Non-Critical Local / Remote

NPTI 20072010

Controller Action
On / Off Proportional / Integral / Derivative Feedback Feed forward Ratio Control Split Range Cascade

Controller Types
PLC / microprocessor / Microcontroller / Electronic Distributed / Centralised Hydraulic / Pneumatic / Electrical
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Elements of Control Loop

Process Measurement System Final Control Element Human Machine Interface Controller / Program
Process Controller (Decision) Measurement (Process Variable)

Action (Final Control Element)

Necessity for Control Loop

For Optimal operation of process within range Sequential execution cannot be applied always Quick response / High sensitivity

NPTI 20072010

Terms related to Control Loop

Set Point (Desired Value) - Auto- Depends on Process flow - Manual Set by operator Controlled Variable (Process Variable) - Parameter in process taken for consideration - e.g.,Deaerator Pressure / Hot well Level Manipulated Variable - Parameter chosen to vary in order to achieve desired set point - e.g., Damper position / TCV position Control Deviation - Error signal that describes difference between SP and PV Command Output - Output to Final control element to correct the deviation
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Desk Control Tiles;HPH6 to DEA / LPH4 2LCV553_063

-20 0 +20
50 100 % 50 0 0 100 +20

-20

10
0

%
100

VALVE POSITION

COMMAND / DEV

48.15 168 PV
M CLS A/M

% 175 SP
A OPN

+50

-50

mmWc AUTO / MAN

SET POINT

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Execution of a Control Loop

Control Task (e.g., SH / RH steam temperature control) Variables to be measured in order to monitor stable performance of loop (e.g., Drum level & Pressure / Feed water flow & Temperature / Steam flow, Pressure & Temperature ) Selection of manipulated variables (e.g., FCV position / Scoop Position) Tuning of control loop / best control configuration (Gain adjustments- Proportional / Integral) Adjusting the manipulated variable based on information/signal received (Command output from controller based on error signal.)
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Control Loops Steam Generator

Furnace draft control Secondary air header pressure control Superheated steam temperature control Reheated steam temperature control

Fuel oil supply header pressure control

Fuel oil temperature control Fuel oil flow control Atomising steam header pressure control Secondary air flow to oil burner control Hopper air flow control Mill outlet temperature control

Load and combustion control

Auxiliary steam pressure control Auxiliary steam temperature control

Feedwater flow control

Air heater average cold end temperature control

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Control Loops Steam Turbine

BFP Scoop Control LP Heater 1 level control LP Heater 2 level control LP Heater 3 level control LP Heater 4 level control BFP recirculation control CEP minimum recirculation flow control MST to Ejector pressure control BFP Seal water temperature control Gland steam pressure control Gland steam temperature control H2 cooler cooling water temperature control

Deareater level control

HP Heater 6 level control HP Heater 7 level control Hot well level control Deareater pressure control

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Boiler Drum Level Control ;Set Point

Control desk / OS

Drum Level
(Compensated)

Feed Water Flow - Steam Flow

Blow down constant

k
Correction factor

M A X

28% - Steam flow Zero

(X)K
PI A /M PI

(X)K

Z/I

A /M

Z/I

I /P

I /P

FCV 1

FCV 2

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Boiler Drum Level Control ;Feed forward

Set Point
Control desk / OS

Feedback

Drum Level
(Compensated)

Cascade
Feed Water Flow - Steam Flow
Blow down constant

k
Correction factor

M A X

28% - Steam flow

Zero

(X)K
PI A /M PI

(X)K

Z/I

A /M

Z/I

I /P

I /P

FCV 1

Redundant Redundant Final controller control element

FCV 2

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LPH 3 LEVEL CONTROL;-

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LPH 3 LEVEL CONTROL;LPH3 level

(0-356 mmWc)

Set Point
(0-356 mmWc)

(X)K

(X)K

PI

os
Z/I
A /M

Z/I

I /P

LPH3 to FT
50-100 %

LPH3 to LPH2
0-50 %

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LPH 3 LEVEL CONTROL;LPH3 level

(0-356 mmWc)

Set Point
(0-356 mmWc)

(X)K

(X)K

LPH2 level High Protection close Z/I

PI

os
A /M

Z/I

I /P

LPH3 to FT
50-100 %

LPH3 to LPH2
0-50 %

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HOTWELL LEVEL CONTROL;Recirculation valve CEP discharge to Hotwell

Main condensate valve CEP discharge to LPH

V a l v e
p o s i t i o n

100% open

0% close

30

100%

Hotwell Level

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HOTWELL LEVEL CONTROL;I/P Recirculation valve CEP discharge to Hotwell

Hotwell

Condensate Extraction Pump

Main condensate valve CEP discharge to LPH

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HOTWELL LEVEL CONTROL;Hotwell level

(0-356 mmWc)

Set Point
(0-356 mmWc)

(X)K

(X)K

LPH2 level High Protection close Z/I

PI

os
A /M

Z/I

I /P

Main condensate valve

CEP discharge to LPH

Recirculation valve CEP discharge to Hotwell

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Loop Consideration; Controller tuning Steady process / manual mode / No load change
Vary proportional / Integral / Derivative gain Observe decay ratio / dead time / integral windup / Control deviation

Increasing Integral action causes CLCS more sensitive

Dead time leads to instability of loop response Implement override control
(e.g, Scoop min 30%, LPH3- LPH2 level high protection close)

Include secondary measurements if necessary (e.g., for MST flow compensation Pressure & Temperature also measured).
Different gain adjustment (e.g., during set point variation High / Low ramp) Measurement / Control transmitters for high resolution (e.g., Hotwell level 0-1600 mmWc / 0-356 mmWc)

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The existence of a control loop does not always mean that the system is capable of controlling to the degree required.

Concerns; Sensitivity and response time of the sensors and transducers. Modes matching to application / controller (Dual loop for SH/RH temp control)

Tuning for specific condition

More Dead time (SH / RH attemperation control) & Hysteresis Final control element size / shutoff / response / power to close against differential pressure (e.g., DP in Feed water control valve) Closed loop compatibility with control system

Criteria for evaluating good control; Stability of process Minimum or no overshoot on startup Minimum time to reach the desired set point
NPTI 20072010