Special Control for super critical

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PMI Revision 00

ADDITIONAL MFT CONDITIONS Furnace vertical wall tube temperature high If water wall tube metal temperatures exceed the set point, automatically trip the fuel following a maximum 3 second time delay. This trip protects the tubes from overheating and potent failure. High water wall tube temperatures are an indication of over-firing, low water wall flow, or a combination of both. Over-firing could be a result of extreme load change rates. Low water wall flow could be a result of excessive SH spray flow.
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 Superheater pressure (both leads) high. Superheater temperature (either side) high for more than twenty seconds. Reheater outlet (either side) temperature high for more than twenty seconds.

ADDITIONAL MFT CONDITIONS

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MFT CONDITIONS
Turbine trip conditions causing vacuum break like axial shift very high, bearing vibration high

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REHEATER PROTECTION LOGIC

Arming - The reheat protection logic is armed or activated once operating conditions are such that there is a potential for steam generator material damage due to overheating. Specifically, total fuel flow > X % (where X corresponds to 538 C furnace flue gas temperature) or steam flow > X % or measured furnace temperature > 538 C.

Initiation of a master fuel trip A loss of main steam flow path (no path through HP turbine or HP bypass, or no flow path through LP turbine or LP bypass). The boiler remains in an over fired condition (total fuel 5% above steam flow) 50 seconds after a turbine trip or fast cutback. HPBP & LPBP not open after generator tripped. HPBP & LPBP not open after turbine tripped.

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PMI Revision 00

Heavy Oil Leak Test/ Light oil leak test All of the following conditions must be present before oil leak test can be started: All heavy oil nozzle valves closed. Heavy oil trip valve closed Open the oil control valve , After fifteen (15) second, open command is sent to the oil trip valve, When the oil trip valve is fully open, the oil return valve is commanded to close. The oil piping downstream of the oil trip valve is now being pressurized, the oil header pressure is indicative at present value.
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Start-Up System with Recirculation

SH

Start-Up System Recirculation Pump in Main Bypass Line

Separator

C HWL

ECO

HPH

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Flash Tank To Condenser Deaerator BFP

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WW

C C

If the water system of the boiler is empty (economizer, furnace walls, separators), then the system is filled with approximately 10% TMCR feed water flow. When the level in the separator reaches set-point, the WR valve will begin to open. When the WR valve reaches >30% open for approximately one minute, then increase feed water flow set-point to 30% TMCR. As the flow increases, WR valve will reach full open and ZR valve will begin to open.

START-UP

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START-UP
The water system is considered full when: The separator water level remains stable for two(2) minutes and The WR valve is fully opened and ZR valve is >15% open for two(2) minutes.

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START-UP contd..
Water flows through the economizer and evaporator, and discharges the boiler through the WR valve to the flash tank and via connecting pipe to the condenser.

Start BCP and open the UG valve to establish minimum water wall flow at 30% TMCR. As the pressure is raised, first the WR and then the ZR valves will open when separator water level increases due to boiler water swell. As pressure further increases, the WR and ZR valves will start to close as the water level decreases.

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START-UP contd
The steam temperature at the separator inlet will reach a stable superheated condition at app. 30% TMCR, causing the level in the separator to decrease and eventually disappear. The boiler is now in once-through mode (dry mode). The BCP (Boiler Circulating Pump) will be stopped automatically. It is extremely important that minimum water wall flow be maintained at all times when firing the boiler to prevent tube damage due to overheating.
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SEPARATOR STORAGE TANK LEVEL CONTROL

Separator level is maintained by the combined action of a separator storage tank level feed water demand and the positioning of WR and ZR drain valves. Feed water demand is developed in response to separator storage tank level error and total fuel flow so as to prevent tank level from dropping too low. The WR and ZR valves are controlled in a split range manner to maintain the liquid level once the level reaches a high limit.

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SEPARATOR STORAGE TANK LEVEL CONTROL

The WR valve will respond first and then the ZR when the WR exceeds its linear operating range. Tank geometry is such that fluctuations in tank level are very dynamic, for this reason, only proportional control action established through the WR/ZR function curves is used to position these valves in response to level error.
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UG VALVE CONTROL
Control objective: Maintain minimum economizer inlet flow. Control action: The boiler circulating pump is started following the start of a turbine-driven feed water pump and the final clean-up cycle. This pump circulates feed water from the evaporator outlet back to the economizer inlet. Located at the outlet of this pump is the UG valve which controls economizer inlet flow during the start-up phase of operation. Demand for this recirculation control valve is established based on measured economizer inlet flow compared to a minimum boiler flow set point.
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Control objective:

FEEDWATER CONTROL LOOP

Develop total unit feed water demand as required to support unit load. Adjust feed water demand to maintain desired separator outlet temperature. Adjust separator outlet temperature set point as required to maintain acceptable platen superheat spray control range. Incorporate separator storage tank level (wet mode) feed water demand. Maintain minimum required economizer inlet flow. PMI Revision 00 .May 24, 2012

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FEEDWATER CONTROL LOOP contd..

Optimization of the feed forward in this manner minimizes temperature fluctuations that may otherwise result from varying dynamic response between the firing and feed water control systems (as they relate to evaporator heat transfer) thereby lessening the dependence on feedback correction. Demand for feed water is established predominately by the Boiler Master demand. This signal, processed though a boiler transfer function provides the feed forward component of the total feed water demand. The boiler transfer function is a tunable dynamic element providing a means to dynamically match the feed water feed evaporator heat transfer. Mayforward demand to actual PMI Revision 00 24, 2012 16

 The first controller acts on a load dependent average platen spray differential temperature. Its output represents the required adjustment to evaporator heat transfer/steam generation to maintain both the steam conditions and flue gas temperatures entering the platen superheat section so as to ensure adequate platen spray control range. A second controller acts on a load dependent separator outlet temperature set point corrected by the platen spray differential temperature controllers output. This controller acts to adjust feed water in response to firing system disturbances and the relatively fast effect they have on separator outlet steam temperatures. The overall combined feed water feedback control action is such that feed water demand is responsive to changes in the overall unit heat transfer profile.
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FEEDWATER CONTROL LOOP contd..

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 The combined feed forward/feedback demand signal is subject to a minimum economizer inlet flow set point (wet mode) activated if the boiler circulation pump is not in service and the unit is being fired. This ensures the minimum economizer inlet cooling flow is maintained by the feed water supply system in the event the start-up system is not available. The feed forward/feedback demand signal is subject to a second wet mode feed water demand developed to support separator storage tank level control. The resulting demand provides the set point to a feed water master controller. The fuel/feed water ratio protection logic provides overriding control of individual feeder speed demands in the event of an excessively high fuel to feed water ratio.
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FEEDWATER CONTROL LOOP contd..

SUPERHEAT STEAM TEMPERATURE CONTROL

Overall superheat steam temperature control is accomplished with adjustment of spray water control and manipulation of feed water flow. The basic concept is such that two final spray water control valves act to maintain final super heater outlet steam temperatures and two platen spray water control valves respond to final spray differential temperatures and feed water flow is adjusted in response to average platen spray differential temperatures. In the short term, final superheat temperature fluctuations are minimized by the fast acting final spray water control valves.

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SUPERHEAT STEAM TEMPERATURE CONTROL

In the long term, control action automatically readjusts steam generation at each control point (evaporator, platen, final) in response to changes in corresponding heat transfer rates. This approach provides a high level of disturbance rejection and ensures the platen and final spray water control valves remain in control range by ultimately adjusting evaporator outlet steam conditions/heat transfer and consequently fire side heat passed to the superheat sections.
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Platen Superheat Temperature Control

The primary objective is to keep the final superheat spray water control valves in their desired operating range. The control structure is a cascade arrangement where the master controller acts on the differential temperature measured across the corresponding final spray station as compared to a load dependent differential temperature setpoint. The output of this controller represents the required temperature entering the platen superheat section to achieve the desired temperature at platen outlet (i.e. corresponding final spray station inlet). An over/under firing feedforward is added to the masters output for improved response. This signal is developed by comparing the rate of change in steam flow to the rate of change in fuel flow. Over firing (rate of change in fuel flow in excess of rate of change in steam flow) decreases the masters output. This is an anticipatory action to offset the tendency for increased steam temperatures resulting from a temporary imbalance between cooling (steam flow) and available heat (firing rate) when over firing.
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Platen Superheat Temperature Control

The signal has the opposite effect when under firing (increases masters output) since in this case the temporary cooling/heat imbalance tends to decrease steam temperatures
The slave controller output, subject to an overriding saturation protection circuit provides the spray valve position demand. Saturation protection prevents over spraying by limiting the final valve demand. Saturated steam temperature is established from measured separator outlet pressure, adding X degrees C establishes the minimum permissible degree of superheat. Increased spray is prevented by limiting the final spray valve demand in the event measured desuperheater outlet temperature drops below the established minimum level of superheat.

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Platen Superheat Temperature Control contd The resulting modified master output provides the set point to a slave controller. This controller acts on this set point as compared to steam temperature measured at the spray stations outlet (i.e. inlet to platen superheat section).

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Final Superheat Temperature Control

Control objective: Control final superheat steam temperature. Control action: The master controller for each valve acts on the corresponding final steam outlet temperature as compared to a load dependent set point. The slave controller positions the final spray valve (subject to saturation limit) in response to the master output (with over/under firing feedforward) as compared to the associated spray station outlet temperature.

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THANK YOU

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