WBC

WGF440/13.7-2 Style Boiler Control Principles Instruction

SS505-22

Drafted By: Checked By: Standardized By: Reviewed By: Approved By:

The People's Republic of China Wuhan Boiler Company Limited 2007. 08

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Control Principles Instruction

SS505-22

Preface
India MPPL1135MW CFB boiler which is a single drum natural circulation boiler with high temperature and super high pressure, single middle reheating, a high temperature insulated cyclone, balanced air draft, coal feeding on front wall, outdoor arrangement. It burns high moisture and high sulfur lignite and it is designed by Wuhan Boiler Company Ltd. and Thermophysics Engineering Institute of Chinese Academy of Sciences and made by Wuhan Boiler Company Ltd. The instruction specifies attentive items in boiler on-off process and normal operation according to design characteristics of this boiler. In accordance with the features of circulating fluidized bed boiler of this type it also gives alarm value of the main control parameters, MFT acting values that provide references for the power plant and design institute when carrying on DCS program, compiling operating rules, running and controlling of the boiler. When reading this instruction, please refer to the following correlative instructions simultaneously: 1. Boiler Product Specification (SS505-1): 2. Boiler Operating Instruction (SS505-7): 3. Other instructions (such as ash cooler, ignition, soot-blowing, regular blow through, etc.): Due to the limited experiences of boiler operation, this instruction will inevitably appear some insufficiencies and unseemliness. If any problem happens in the operation, please contact with our company technicians in time. Statement: This instruction is only used for Shandong Power Construction No.3 Company, the user of this plant and the design institute as well as only for this project. Any other unit and individual are forbidden to copy or extract any content from this instruction.

Countersign
Specialty Proper Combustion Signature Date

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Control Principles Instruction

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CONTENTS
1. GENERAL RULES.........................................................................................1 2. SAFETY MEASURES OF RUNNING .........................................................1
2.1 Basic requirements............................................................................................................................................1 2.2 Measuring points description...........................................................................................................................1 2.3 Limitations of subatmospheric pressure in the furnace................................................................................1 2.4 Drum water level and temperature difference requirements .......................................................................2 2.5 Excess air requirements ...................................................................................................................................2 2.6 Furnace bed temperature limitations..............................................................................................................2 2.7 Limitations of air flow and air pressure in the air chamber in the furnace ................................................3 2.8 Protection of reheater pipes .............................................................................................................................3 2.9 Safety valve regulation......................................................................................................................................3 2.10 Control of steam temperature .......................................................................................................................4

3. OPERATION AND CONTROL OF BOILER..............................................4

3.1. Strategies and requirements of the furnace safety monitor system.............................................................5 3.2 Strategies and requirements of regulation and control ..............................................................................10

4. BOILER FUNCTION CURVES..................................................................15

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1. General rules

Control Principles Instruction

SS505-22

(1) The contents in the following sections can not be regarded as operating regulations of the boiler unit. When the power plant compiles and improves its operating regulations instructions about the boiler, auxiliary equipment and the instruction of initial operation of the boiler could be used to referring as a instructing datum. (2) Security of the boiler should be paid attention to in the operating and running. Circulating fluidized bed combustion technology is different from pulverized coal combustion technology and other combustion technologies. Circulating fluidized bed boiler doesnt have obvious fireballs in the furnace. It contains plentiful circulated solids that carrying a lot of heat. (3) Before start-up boiler unit the operating workers should be fully familiar with structure and function of the boiler, assemblies, control system and auxiliary equipments. (4) Operating workers should be know the working conditions of each assemblies and auxiliary equipments as well as pay attention to actual operating conditions when star-up and in operation of the boiler according to system requirements.

2. Safety measures of running

2.1 Basic requirements (1) Operating workers must abode by and carry out prevention and safety measures that talked in this chapter in the operating of each stages. (2) The boiler doors in the positive pressure area (such as lower parts of furnace, loop seal and so on) shouldnt be opened in the operation to avoid injuries of workers because of effusion of fume and hot granules. 2.2 Measuring points description The measuring points arranged in this project could be seen in the boiler measuring point arrangement drawings. Measuring point operation values, range of measuring, the maximum value, acting value and so on could be seen in diagram 1 measuring point instruction. Values in the measuring point instruction are values at 100%B-MCR for design fuel. They could be adjusted according to running experience. 2.3 Limitations of subatmospheric pressure in the furnace Exorbitant subatmospheric pressure or exorbitant positive pressure in the furnace will results in serious deterioration of the unit and auxiliary equipments. So furnace pressure should be controlled strictly when unit is running and the following automatic control system should be used safely before boiler start-up. (1) In furnace subatmospheric pressure (pressure of balance point measured at the furnace outlet) should be inspected and controlled automatically in 200Pa. (2) Running workers do not allow the pressure of furnace balance point over 500Pa (alarm value).
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Control Principles Instruction

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(3) MFT (main fuel trip) should be set in the furnace outlet pressure value of 2500Pa and with 5 seconds delay. (4) Forced and induced draft fans trip should be set in the furnace outlet pressure value of 3500Pa (without delay). (5) After forced fans, induced draft fans and all of the loop seal high pressure blowers shut off (using MFT action to make fans shut off) the collapsed bed materials still occur combustion. So access door must keep closed .When start-up again the air flow should be entered in slowly in order to blow combustible in the boiler out of the unit. 2.4 Drum water level and temperature difference requirements (1) Normal water level of the drum is below drum centerline 150mm.Alarm water level is set in 100mm relative to normal water level. Shutdown water level is set in 175mm and -200mm relation to the normal water level. (2) When the drum is at the lowest water level (water level lower than normal water level 200mm) or at the highest water level (water level higher than normal water level 175mm) should carry on MFT and cut off forced fans and induced draft fans. (3) To prevent the drum from excessive thermal stress variation ratio of the steam drum metal wall-temperature should be lower than 55/h. The temperature difference between the up wall temperature and the down wall temperature of the drum should be controlled less than 40.The up wall temperature and the down wall temperature of the drum should be inspected and the temperature difference instruction should be set in the master control room. (4) Operating workers should pay attention to that there is a lot of heat in furnace even after the MFT. Therefore, we must keep the water level of the drum in normal range all the time and maintain appropriate steam output in order to control variety of the steam pressure. 2.5 Excess air requirements To maintain good combustion conditions we should pay attention to ensuring appropriate coal-air ratio by controlling excess air ratio at the furnace exit. In the normal running of the boiler the excess air ratio at the furnace exit is controlled by measuring the dust oxygen content of second pass at the exit. At maximum continuous combustion rate the corresponding oxygen content should be controlled in about 2.7% (volume ratio, take dry gas as benchmark). 2.6 Furnace bed temperature limitations The bed temperature is measured by 20 thermocouples arranged in the middle-lower parts of furnace. Normal bed temperature of the boiler running range is 800 920. Bed temperature should be inspected strictly when boiler is operating and make sure the boiler running in this temperature range. The high-level alarm value of bed temperature is 980.When temperature reaches to 1000 automatically MFT should be carried on. The lowest running bed temperature is 700. Without combustion-supporting it does not allow bed temperature below this temperature. The low-level alarm value of the bed temperature is 600. When the bed
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Control Principles Instruction

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temperature as low as 550 automatically MFT should be carried out or dive into above-bed assisted combustion or off-bed auxiliary burners. But when bed temperature below 550 whether auxiliary and air duct ignition combustion is operating or not MFT should be carried out. According to the accumulated operating experiences and different emphasis between combustion efficiency of the boiler and desulfurization and nitrogen efficiency in the case of ensuring the boiler without slag bed temperature could properly regulate according to actual running bed temperature of the boiler. In the running if the local bed temperature appears rising it should increase primary air mass flow of the furnace bottom to improve local bad fluidizing conditions. 2.7 Limitations of air flow and air pressure in the air chamber in the furnace (1) When the boiler operates normally the air chamber static pressure below the furnace distributor should maintain between 8000 and 16000Pa.When air chamber static pressure is below 6000Pa low limitation alarm of the air pressure will be sent out. If air chamber static pressure is over 18000Pa high limitation alarm of the air pressure will be sent out (2) When the primary air flow of distributor is below 10104Nm3/h air flux low limitation alarm will be sent out. (3) Carry out MFT if it happened following situations: a. Air chamber pressure in the furnace is above 20000Pa and delays 10 seconds; b. Air pressure in the air chamber is below 6000Pa and delays 10 seconds; c. Primary air mass flow of the main flue to the furnace floor is below 10104Nm3/h and delays 10 seconds. 2.8 Protection of reheater pipes When start-up if reheater doesnt have steam the flue gas temperature at furnace exit should control below 500 in order to prevent platen reheater pipes from burnout. When the boiler star-up or shutdown we should open the high-pressure bypass system to protect reheater. Until the bed temperature below 500 it is permitted to close highpressure bypass system. At the MFT we should open the high- pressure bypass system. Some parts of the steam will be cooled through reheater pipes to prevent from burnout. 2.9 Safety valve regulation Regulation and checkout of safety valves should be carried on according to instructions of the safety valves. The setting pressure and discharge amount of various safety valves could be seen in the following table:

Installation position and name

Setting pressure Discharge amount

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#

Control Principles Instruction

MPa 15.74 16.21 14.30 14.44 3.07 3.15 2.80 2.99

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t/h 172.17 177.25 49.51 49.99 139.25 142.60 47.01 37.90

Drum safety valve 1 Drum safety valve 2# Superheater safety valve 1# Superheater safety valve 2# Reheater safety valve at inlet 1# Reheater safety valve at inlet 2# Reheater safety valve at outlet 1# Reheater safety valve at outlet 2# 2.10 Control of steam temperature In order to monitor start-up conditions we set up wall- thermocouple to measure steam temperature at the relational components of stream circuitry to confirm allowable heating-up velocity. Component Drum Platen superheater Low temp. superheater High temp. superheater Low temp. reheater Position Top and bottom parts Upwards platen: top parts Downwards platen: at subjacent outlet of platen Outlet pipeloop (even distribution in furnace width) Outlet pipeloop (even distribution in furnace width) Outlet pipeloop (even distribution in furnace width) NO. Up-down 6 apiece 8 8 22 Alarm temperature value Temperature difference between 40 temperature variety 55/h / 495 430

22

550

22

480

High temp. at subjacent outlet of platen 12 550 reheater These above-mentioned thermocouples arrange in the region that can not be swept by flue gas so measured temperature could be regarded as medium temperature of the pressure parts. These thermocouples and other thermocouples (including detector in the control center) should be examined and ensure that they could use momentarily. When boiler is operating if the steam temperature doesnt exceed utmost alarm range showed in the following table the boiler could carry on continuous operation. As alarm appearing workers should regulate operating conditions to protect the safety of the equipments.

3. Operation and control of boiler

Because operation and control system of the boiler is not in the supplied range of the boiler manufacturer and the operating experiences of the boiler maker is finite. The following content is just a suggestion of the boiler manufacturer:
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Control Principles Instruction

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3.1. Strategies and requirements of the furnace safety monitor system The primary function of the furnace safety monitor system is to implement orderly management of boiler combustion system. When permission conditions are satisfied the program controls burners to start-up and shutdown the boiler as well as to maintain burners operating steadily. When permission conditions are not satisfied we should carry on safe logic which is designed advanced and essential safeguards for boiler to protect safety of workers and equipments. These safeguards consist of rapid drop of load, shutdown of the boiler, sootblowing of the furnace after shutdown and so on. Primary functions of the furnace safety monitor system are: (1) The flame monitoring; (2) The furnace pressure monitoring; (3) Burners management; (4) MFT; (5) Furnace soot-blowing; (6) Other interlock and monitor items. Primary conditions joined in boiler protection interlock are: (1) Boiler temperature permitted range; (2) Steam drum water level is not low; (3) Steam drum water level is not high; (4) Air pressure of high-pressure is not low; (5) Instrumentation blast pressure is not low; (6) Furnace pressure is not high; (7) Operation of secondary fan; (8) Operation of induced draft fan; (9) Operation of primary fan; (10) No BMS trouble; (11) Fuel-air ratio is normal; (12) No losing superheater protection signal; (13) No emergency trip signal; (14) Proper primary air mass flow to the air distributor; (15) No DCS trouble; Losing any of the conditions that has been mentioned above the boiler will carry on MFT. After MFT it would carry on furnace soot-blowing for 5 minutes and the primary conditions are as follows: (1) The total air flow of the boiler is larger than soot-blowing air flow; (2) All the flaps are open; (3) No fuel is put in; (4) ed temperature is less than 700.
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Control Principles Instruction

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When the MFT occurs it will appears following actions: (1) Stop flue burner (under-bed burner); (2) Stop above-bed start-up burner; (3) Stop coal feeder and rotary valve; (4) Stop limestone feeder and rotary valve; (5) Close latch valves of first and secondary spray water; (6) Close main oil trip valves; (7) Set total air flow in minimum; (8) Turn the secondary air spray nozzle control to manual actuated. The main conditions joined in flue and above-bed burner interlock are: (1) Main oil piping trip valve is open; (2) Main oil piping trip valve is close; (3) Main oil piping pressure is low; (4) Main oil piping pressure is high; (5) Ignition is permitted; (6) Main oil piping trip valve conditions is satisfied; (7) Single burner ignition is permitted; (8) Air flow of the single burner is more than the minimum value; (9) Oil pressure of the single burner is low; (10) Oil gun of the single burner is in place; (11) Oil valve of the single burner is open; (12) Oil valve of the single burner is close; (13) Burner is on the spot; (14) Burner of the single burner is dived into using; (15) Single burner has fire; (16) Single burner flame is lost; (17) Oil regulation valve of the single burner is in minimum position; (18) Single burner soot-blowing is closed; (19) Single burner is soot-blowing; (20) Single burner is prepared; (21) Single burner request for soot-blowing; (22) Single burner is operating; (23) Single burner refuses to close; (24) Single burner refuses to open. Logic diagram

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Purge logic (see Chart 2)

Control Principles Instruction

Finish the purge Permit to release MFT relay

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MFT logic [see Chart 1(b)] Main fuel trip(MFT)

N O T

A N D A N D

Burner logic in flue Solid fuel logic (see Chart4)

Chart 1(a) Interlock system program

Trip mail fuel Loose induced draft fan Loose forced draught an Drum water level is low Furnace pressure is high Air flow <25% full load air flow Loose boiler circulation (if it is applicable)
O R

Revert to MFT delay (from purge logic)(see Chart 2)

Stop strike fire (see Chart3) Close all the safety disengaging valve of single burner in flue(see Chart3) Close all the safety disengaging valve of single burner header(see Chart3) Stop all the solid fuels and sorbent feeding system(see Chart 4)

Exsite MFT relay

Establish arbitrary coal feeder Establish arbitrary burner in flue All the fuel input is 0 With enough bed temperature Bed temperature is low Burner in flue does not have flame confirmation
A N D

RESET

O R

SET

A N D O R A N D

A N D

To purge logic

Manual trip

Chart 1(b) Boiler trip logic program

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Control Principles Instruction

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Boiler air flow more than purge air flow

All the air paths in purge position It has been started and completed 5 times volume or purged for 5minutes (bed hasbeen fluidized)

All the required air regimes is operating All the fuel feeding equipments have tripped and all the safty valves have closed Conditions of the boiler trip have been removed (see Chart 1(b))

A N D

O R

A N D A N D

Purge of the main fuel and burner in flue have been completed

Bed has been fluidized and the bed temperature is above ignition limit

Permit to replace MFT relay

Chart2 Purge logic

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Control Principles Instruction

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Igniter "Sparkless" O R Stop striking fire

MFT(see Chart 1(b)) MFT relay (see Chart1 (b)) Burner in flue"Flameless" Pressure of burner in flue is dissatisfied burning source Air used for cobustion of burnerin flue is not sufficient Fans for supplying combustion air is lost or air flow for supplying burner in flue is not sufficient Fuel header pressure(measuring) for burner in supplying flue is high or low Pressure of fuel to burner in flue is low Close safty disengaging valve of burner header in flue Close safty sidengaging valve of single burner in flue

O R

O R

Chart 3 Burner for warm-up safety subsystem

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Permissions of solid fuels bed temperature are dissatisfied MFT(see chart 1 (b))

Control Principles Instruction

MFT relay (see Chart 1(b))

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Bed temperature is low Parts of solid fuel feeding system is in trouble Withour confirmation of burner in flue Bed has not fluidized

A N D

O R

Trip of solid fuel feeding system

Trip of superior feeding system equipment

Chart 4 Solid fuel safety subsystem 3.2 Strategies and requirements of regulation and control The main functions of regulation and control system are (They dont belong to design range of the boiler manufacturer): (1) Boiler main control; (2) Feed water control; (3) Steam temperature control; (4) Secondary air control; (5) Primary air control; (6) Air heater (primary air temperature) control; (7) Bed temperature control; (8) Induced draft control; (9) Fuel control; (10) Limestone control; (11) Bottom ash control; (12) Burner and its air control; Control circuit description (1)Boiler load control circuit Boiler load signal consists of measuring signals of main steam header pressure and actual steam mass flow. Requirement signal of the boiler load make fuel rate (oil and coal) and needed air mass flow change. The precondition is to maintain main steam pressure in setting value to change needed steam mass flow, fuel exothermical value and the whole heat10

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Control Principles Instruction

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transfer process. (2) Mass flow compensation control circuit Measuring value of total fuel mass flow (coal and fuel oil) regards as feedback signal of the coal mass flow control circuit and required amount signal of the air flow control circuit must consider some changes of the boiler heat transfer status and fuel heat value. Therefore, total fuel flow must be compensated. (3) Feed water mass flow control circuit This circuit design must ensure that balance between feed water flow of the boiler and that of steam flow in order to maintain the required water level in drum. During the start-up period above process is realized by controlling the opening degree of the start-up feed water regulate valve. In normal operating period above process is realized by controlling the opening degree of the main feed water regulate valve. These two valves receive their control signals respectively from single momentum controller or three- momentum controller. The single momentum control could control automatically but also could control manually. Threemomentum control could cascade control but also could control manually in operation. Single momentum control inspects steam drum only and is used in start-up. Three- momentum control inspects drum water level, steam mass flow and feed water mass flow. It has high control level and is used in the steady heavy load condition. (4) Primary air heater control circuit The control system is used to control the cold end temperature of air preheater to ensure this temperature higher than the dew point of the vitriol in the flue gas. This can prevent from corrosion of the air heater cold end metal. Before air enters into primary air heater we should adjust steam mass flow entered into air heater in order to ensure enough primary air in air preheater and make flue gas average temperature at the air heater outlet higher than the dew point. This average temperature is named cold end temperature. According to sulphur content in the fuel the setting value of the cold end temperature could be sure. In addition to reduce the possible corrosion of the air preheater before start-up and low load operating until reach to normal gas temperature at outlet cold end air preheated and joined in combustion could reduce consumption of the fuel. (5) Steam temperature of the superheater control circuit The whole steam temperature control is divided into two segments to complete. In the first segment temperature of steam left SH1would be controlled by spraying water. This control is based on cascade adjustment. The main controller responds according to the temperature difference between the temperature at SH2 outlet and the main setting value of the manual actuated. Assistant controller responds according to temperature difference between modified temperature by main controller and the temperature at SH1 outlet. Make sure the temperature of the steam left SH2 in 473. In the second segment temperature of steam left SH2would also be controlled by spraying water. The control is based on cascade
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Control Principles Instruction

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adjustment. The main controller responds according to temperature difference between the temperature at SH3 outlet and the setting value of the manual actuated. Assistant controller responds according to temperature difference between modified temperature by main controller and temperature at SH2 outlet. The final main steam temperature left boiler controls in 540. (6) Steam temperature of reheater control circuit The whole steam temperature control is realized by spraying water of desuperheater to control temperature of steam left reheater. This control is based on cascade adjustment. The main controller responds according to temperature difference between temperature at RH2 outlet and the setting value of the manual actuated. Assistant controller responds according to temperature difference between temperature modified by main controller and temperature at RH1 outlet. The final temperature of steam left reheater is controlled in 540. (7) Bed temperature control circuit The purpose of this circuit is to keep bed temperature at setting value according to load demands. The setting value is 870. Operating in this temperature could ensure optimal combustion efficiency and optimal desulfuration efficiency. For controlling bed temperature at this level the ratio of the primary air and the secondary air should change with bed temperature. (8) Primary air flow control circuit The air provided by primary air fans has following functions: a. As sealing air for coal feeder. b. The primary air passing through the air distributor using for fluidizing bed material in the combustor. c. As combustion air put in two off-bed burners when start-up using oil to produce enough high temperature flue gas. d. As fuel spreading wind. (9) Secondary air flow control circuit The preheated air provided by secondary fans has following functions: a. These are 26 secondary air nozzles on the four sides of the combustor wall. The secondary air entered into these nozzles can be used for the full combustion of the fuel to help control bed temperature and adjust excess air flow of the combustor. b. As cooling air of 4 above-bed burners. (10) Control modes and requirements of the air flow damper There are 4 dampers are set on up and down parts of secondary air main piping at the both sides of the boiler. According to operating conditions regulate dampers properly to gain the optimal combustion effect. Air distribution of the above-bed burner: Every start-up burner has a damper regulator. After converting the oil mass flow of the burner into combustion air flow (excess air ratio 2) and comparing with actual measured air flow. Consequently opening degree of the air
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Control Principles Instruction

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damper is controlled. During start-up burner exit operation the damper should be set at a fixed opening degree. Cold air flow of the single burner can not lower than 8788 Nm 3/h to protect the burner injections from burnout. Air distribution of the off-bed burner: There are 2 off-bed burners. Every start-up burner has 3 damper regulators. They are a damper used for oil burner combustion, a cooling air dampers and a main fluidizing air damper. At start-up the main fluidizing air damper is closed. After converting the oil mass flow of the burner into combustion air flow (excess air ratio 1.1) and cooling air flow (excess air ratio 3), then comparing with actual measured air flow. Consequently opening degree of the air damper is controlled. During the initial startup period the damper could reduce gradually to protect temperature excursion of precombustion pot after cooling air dampers opened entirely. After burner outage the main fluidizing dampers opened gradually, air dampers for combustion and dampers for cooling are closed gradually to maintain total primary air s flow at the bottom of furnace. (11) Furnace draft (subatmospheric pressure) control circuit The boiler is balance draft boiler which is defined as by controlling the discharge amount of combustion product and excess air amount relative to feeding in order to maintain the pressure of a certain characteristic point constant in the furnace. The pressure balance point of this boiler is set at furnace outlet. Induced draft fan sucks flue gas from dust separator and vents cleanly flue gas to stack. Subatmospheric pressure of furnace could be realized by controlling the damper opening degree of the induced draft. (12) Bed pressure control circuit The purpose of the circuit is to control amount of bed material in the combustor. The amount of bed material in the combustor is direct ratio of bed pressure. Not only bed pressure but also bed material inventory will have a direct effect on bed temperature and heat transfer efficiency. Besides it also affects the desulfurization efficiency. Bed pressure is reflected by pressure of furnace wind box. In operation it is necessary to maintain static pressure of wind box in a certain range. (13) Oil mass flow of the burner control circuit The boiler sets 2 off-bed start-up oil burners. The purpose of these burners is to maintain the requirement of main steam pressure during the start-up and shutdown period and enhance bed temperature to reach to coal ignition temperature. Change the capability of oil guns by controlling opening degree of oil regulator valves and subsequently control air temperature of off-bed wind box. (14) Limestone feeding control circuit The purpose of the circuit is to provide sufficient limestone in furnace to maintain discharge amount of SO2 lower than allowable value of environment protection and also provide bed materials. According to discharge density of SO2 at boiler outlet to control the amount of limestone entering the furnace.

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Control circuit Boiler load control Feed water mass flow control Superheater temperature control Bed temperature control bed pressure control Furnace draft control

Control Principles Instruction

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(15) An attachment of Control circuit Regulated parameter Main steam mass flow and pressure Drum water level Superheater temperature Bed temperature Bed pressure Furnace draft Control variable coal feed mass flow, oil mass flow Feed water mass flow desuperheated water mass flow ratio of primary air and secondary air Tapping mass flow Flue gas mass flow Primary air mass flow secondary air flow Forced air mass flow Oil mass flow air distribution air heater steam mass flow Control components Feeder revolution numbers, oil-firing regulator valve feed water regulator valve Speed governing feed pump desuperheat water regulator valve primary air and secondary air control dampers Roller ash cooler rate rotational speed control damper at induced draft fan inlet Guide vane at primary air fan inlet Total damper of secondary air mass flow Guide vane at forced fans inlet oil regulator valve air flow damper of burner air heater steam mass flow regulator valve

primary air Primary air mass flow, flow control bed temperature secondary air Oxygen content in flue, flow control bed temperature capability control Pressure at of forced fans forced fans outlet Oil mass flow control Off-bed wind box of the start-up oil temperature burner air temperature cool end temperature of the primary air of air preheater heater control

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4. Boiler function curves

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This section provides function curves of the boiler. It is only a reference for designing boiler control system.

Correction factor of man steam mass flow

Temperature correction factor of the main steam mass flow

1.4 1.3 1.2 1.1 1.0 0.9

Main steam temperature 350

400 500

Correction factors of main steam mass flow 1.3489

600 700 800

1 0.8 300 2 3 4 5 6

400 1.1860 Temperature of main steam 500 540 600 700 1.0386 1.0000 0.9523 0.8898

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Control Principles Instruction

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Temperature correction factor of feed water mass flow

1.2
Correct ion factor of feed water mass flow

1.1

1.0

0.9

0.8 0 100 200 300 400

Temperature of feed water

Feed water temperature 1 2 3 4 5 6 0.0 100.0 200.0 248.0 300.0 325.0

Correction factor of feed water mass flow 1.1151 1.0915 1.0391 1.0000 0.9472 0.9075

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Control Principles Instruction

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Pressure correction factor of main steam mass flow

1.2 1.0
Correct ion factor of main steam mass flow

0.8 0.6 0.4 0.2 0.0

0.0

5.0

10.0

15.0

20.0

Pressure of main steam MPa

1 2 3 4 5 6 7 8 2.4 9 10
2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.00

Main steam pressure Correction factor of MPa main steam mass flow 0.0 0.0812 2.0 0.3743 4.0 0.5264 6.0 0.6463 8.0 0.7500 10.0 0.8434 Pressure12.0 correction factor of drum water level (gain) 0.9300 13.7 1.0000 15.0 1.0509 16.0 1.0894

Gain

17

5.00

10.00

15.00

20.00

Drum pressure MPa

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Control Principles Instruction

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1 2 3 4 5 6 7 8 9 10 11 12 13 14
400.0 350.0 300.0

Drum pressureMPa Gain 0.00 1.0000 1.50 1.1206 3.00 1.1918 4.50 1.2568 6.00 1.3219 9.00 1.4648 11.00 1.5786 12.00 1.6444 13.00 1.7181 14.00 1.8025 14.99 1.9086 16.00 2.0192 17.00 2.1659 18.00 2.3570 Pressure correction of drum water level (deviation)

Devi ation mm

250.0 200.0 150.0 100.0 50.0 0.0 0.00

18

5.00

10.00

15.00

20.00

Drum pressure MPa

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Control Principles Instruction

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1 2 3 4 5 6 7 8 9 10 11 12 13 14

Drum pressureMPa 0.00 1.50 3.00 4.50 6.00 9.00 11.00 12.00 13.00 14.00 14.99 16.00 17.00 18.00

Deviationmm 0.0000 38.9471 60.5434 79.5728 98.1170 137.4645 167.8156 185.0398 204.1640 225.7904 252.7080 280.5072 317.0345 364.2074

Temperature correction of the total secondary air mass flow

1.2

Co rre ctio n fact or of air ma ss flo w

1.1

1.0

0.9

0.8 0 10 20

30 19

40

50

60

70

80

Temperature of secondary air

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Control Principles Instruction

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1 2 3 4 5 6 7 8 9

Total secondary air temperature () 0.0 10.0 20.0 32.0 40.0 50.0 60.0 65.0 70.0

Correction factor of air mass flow 1.0622 1.0432 1.0253 1.0000 0.9920 0.9765 0.9617 0.9546 0.9476

Temperature correction of the total primary air mass flow

1.4

1.2

Correction factor of air mass flow

1.0 0.8 0.6 0 50 100

Temperature of primary air

20

150

200

250

300

350

400

450

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Control Principles Instruction

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1 2 3 4 5 6 7 8

Primary air temperature 0.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0

Correction factor of air mass flow 1.3693 1.1715 1.1001 1.0403 1.0000 0.9452 0.9065 0.8721

Temperature correction of the secondary air flow

1.4 1.3 1.2 1.1

Correction factor of air flow

1.0 0.9 0.8 0.7 0 50 100 150 200 250 300 350 400 450

Temperature of secondary air

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Control Principles Instruction

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1 2 3 4 5 6 7 8

Secondary air temperature () 0.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0

Correction factor of air flow 1.3693 1.1715 1.1001 1.0403 1.0000 0.9452 0.9065 0.8721

Temperature correction of fuel spreading air mass flow

1.4 1.3 1.2 1.1

Correction factor of air mass flow

1.0 0.9 0.8 0.7 0 50 100 150 200 250 300 350 400 450

Temperature of fuel spreading air ()

22

WBC

Control Principles Instruction

SS505-22

1 2 3 4 5 6 7 8

Fuel spreading air temperature () 0.0 100.0 150.0 200.0 250.0 300.0 350.0 400.0

Correction factor of air flow 1.3693 1.1715 1.1001 1.0403 1.0000 0.9452 0.9065 0.8721

Relation of oxygen content and steam mass flow

18.0
E xc es s ox yg en co nt en t %

16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0 0 100 200 300 400 500 600
Steam mass flow t/h

23

WBC

Control Principles Instruction

SS505-22

1 2 3 4 5 6 7

Steam mass flow t/h 65.0 123.8 200.0 220.0 303.0 398.0 440.0

Excess oxygen content % 14.3000 9.7000 4.0000 2.7000 2.7000 2.7000 2.7000

Relation of controller output and correction factor of oxygen content

1.4
cor rect ion fact or of oxy gen con tent

1.2

1.0

0.8

0.6 0 20 40 60 controller output of oxygen content % 80 100

24

WBC
1 2 3

Control Principles Instruction

Controller output of oxygen content % 0.0 50.0 100.0 Correction factor of oxygen content 0.80 1.00 1.20

SS505-22

Relation of deviation amount of bed temperature manual actuated and primary air flow

15.0
Primar y air flow Km3/h

10.0 5.0 0.0 -5.0

-10.0 -15.0 -60 -40 -20 0 20 40 Deviation amount of bed temperature manual actuated % 60

Deviation amount of bed temperature manual actuated

25

Primary air flow

WBC
1 2 3

Control Principles Instruction

% -50.0 0.0 50.0 KNm3/h -10.00 0.00 10.00

SS505-22

Relation of deviation amount of bed temperature manual actuated and upper secondary air flow

10.0
Upp er seco ndar y air flow Km3 /h

5.0

0.0

-5.0

-10.0 -60 -40 -20 0 20 40 Deviation amount of bed temperature manual actuated % 60

Deviation amount of bed temperature manual actuated

26

Upper secondary air flow

WBC

Control Principles Instruction

% KNm3/h -5.00 0.00 5.00

SS505-22

1 2 3

-50.0 0.0 50.0

Relation of deviation amount of bed temperature manual actuated and middle and lower secondary air flow

10.0

5.0

Middl e and lower second ary air flow Km3/h

0.0

-5.0

-10.0 -60 -40 -20 0 20 40 60

Deviation amount of bed temperature manual actuated %

Deviation amount of bed temperature manual actuated % 1 2 -50.0 0.0

Middle and lower secondary air flow KNm3/h -5.00 0.00

27

WBC
3

Control Principles Instruction

50.0 5.00

SS505-22

28

No. 1 2 3 4
29

Measuring name Feed water mass flow Total desuperheated water mass flow of superheater Feed water temperature in front of operation floor Pressure at economizer inlet Temperature at economizer inlet Temperature at economizer outlet Drum up and down walltemperature measuring point

Qty 1 1 1 2 1 2 6 pairs

Table 1 Measuring point description Range of Running Function measuring value (a reference) Regulate feed water 0550t/h 440t/h flow Monitor Correction of feed water flow Monitor for spot, remote transmission monitor BTU compensation Monitor 21.94t/h 248 15.35MPa 248 300 342, temperature difference is 40 100 050t/h 0400 025MPa 0400 0400

Arranging location Feed water pipeline Superheater desuperheated water total pipe Feed water pipeline Feed water pipeline Feed water pipeline Economizer outlet header Drum

WBC
Control Principles Instruction

Remarks

Maximum 32t/h

5 6

Monitor

0400

8 9

Drum water level alarm Drum water level automatic regulating

2 3

Interlock protection Water level regaulating

300

Drum Drum

Acting value: <200mm or >175mm

SS505-22

No.

Measuring name

Qty

Table 1 Measuring point description Range of Running Function measuring value (a reference) Protection Monitor, correct stream drum water level pressure Monitor Monitor Monitor, correct spay water mass flow Monitor Monitor Regulate spay water mass flow monitor, correct spay water mass flow Monitor Monitor and Regulate spay water mass 14.99MPa

Arranging location

Remarks Acting value 14.991.08MPa Acting value 14.991.05MPa

WBC

10

Connect with spring safety valve Drum pressure measuring point Metal wall-temperature at SH1 outlet tube Steam temperature at SH1 outlet Steam temperature at SH2 inlet Metal wall-temperature of SH2 upwards panels tube Metal wall-temperature of SH2 upwards panels tube SH2 outlet steam temperature SH3 inlet steam temperature Metal wall-temperature of SH3 outlet tube SH3 outlet steam temperature

Drum

11 12 13 14 15 16 17 18 19 20
30

5 22 4 6 8 8 4 6 22 4

14.99MPa 430 410 394 455 495 473 452 550 540

025MPa 0800 0600 0600 0800 0800 0600 0600 0800 0~600

Drum

Control Principles Instruction

At SH1 outlet At SH1 outlet pipe At SH2 inlet pipe Upper parts of SH2 upwards panel At SH2 outlet At SH2 outlet pipe At SH3 inlet pipe At SH3 outlet Main steam outlet pipeline

SS505-22

No.

Measuring name

Qty

Table 1 Measuring point description Range of Running Function measuring value (a reference) flow

Arranging location

Remarks

WBC

21

Connect with spring safety valve

Protection

13.70MPa

SH3 outlet header

22
31

Connect with spring safety valve

Protection

2.454MPa

Reheater outlet header

23

Connect with spring safety valve Reheater inlet steam temperature Low temp. reheater inlet steam temperature Metal wall-temperature of low temp.reheater Low temp. reheater outlet steam temperature High temp. reheater inlet steam temperature

Protection

2.605MPa

Reheater inlet header 0600 0600 0800 0~600 0~600 Reheater inlet header Pipeline at reheater steam inlet RH1 RH1 outlet pipeline RH2 inlet pipeline

24 25 26 27 28

4 6 22 4 6

Protection Monitor Monitor Monitor Monitor and regulate

326 326 480 459 452

Acting value 14.30MPa Acting value 14.44MPa Acting value 2.80MPa Acting value 2.99MPa Acting value 3.07MPa Acting value 3.15MPa Acting value 366

Control Principles Instruction SS505-22

No.

Measuring name High temp. reheater outside track pipe metal walltemperature High temp. reheater outlet steam temperature Reheater desuperheated water mass flow Superheater desuperheat water mass flow Superheater desuperheat water mass flow Reheater Accidental spay water mass flow Wall-temperature measuring point of off-bed burner Outlet flue gas temperature measuring point of off-bed burner Furnace compartment pressure Water-cooling air box temperature measuring point

Qty

Table 1 Measuring point description Range of Running Function measuring value (a reference) Monitor Monitor and regulate Monitor Monitor Monitor Monitor 550 540 2.78t/h 8.3t/h 2.8t/h 0t/h 0800 0600 08t/h 015t/h 08t/h 010t/h

Arranging location RH2 RH2 outlet pipeline Reheater desuperheater Superheater desuperheater Superheater desuperheater Accidental desuperheater On the burner precombustion pot inside wall At burner outlet Furnace compartment Water-cooling air box

Remarks

WBC

29 30 31 32 33 34
32

12 4 2 2 2 2

Maximum 3t/h Maximum 11.5t/h Maximum 4.5t/h Maximum 10t/h Acting value >1100 Acting value >900

Control Principles Instruction

35

Monitor and control

900

01300

36 37 38

4 4 2

Monitor and control Regulate ash discharge Monitor

850 14500Pa 260

01300 022000Pa 01300

SS505-22

Operating range 800016000Pa

No.

Measuring name Pressure of combustor emulsion zone lower parts Pressure of combustor emulsion zone middle parts Pressure of combustor emulsion zone upper parts Bed temperature of combustor emulsion zone lower parts Bed temperature of combustor emulsion zone middle parts Bed temperature of combustor emulsion zone upper parts Combustor outlet pressure SH3 inlet flue gas temperature SH1 inlet flue gas temperature SH1 outlet flue gas temperature

Qty

Table 1 Measuring point description Range of Running Function measuring value (a reference) Monitor and regulate ash discharge Monitor 7000Pa 015000Pa

Arranging location Combustor emulsion zone lower parts Combustor emulsion zone middle parts Combustor emulsion zone upper parts Combustor emulsion zone lower parts Combustor emulsion zone middle parts Combustor emulsion zone upper parts Combustor outlet At SH3 inlet Cagewall superheater Cagewall superheater

Remarks

WBC

39

10

40

4000Pa

06000Pa

Control Principles Instruction

41

Monitor

2000Pa

04000Pa

33

42

10

Control and monitor

870

01300

43

10

Control and monitor

870

01300

44 45 46 47 48

10 10 2 2 2

Monitor Monitor, protect and regulate Monitor Monitor Monitor

870 0 820 690 551

01300 200Pa 01300 0~800 0800

Acting value >3500Pa

SS505-22

No. 49 50 51 52 53 54 55 56 57 58 59 60 61

Measuring name Economizer inlet flue gas temperature Economizer outlet flue gas temperature Oxygen content measuring point at economizer inlet flue Temperature measuring point at air preheater outlet flue Temperature measuring point at cyclone inlet flue Temperature measuring point at cyclone outlet flue Pressure measuring point at cyclone inlet flue Pressure measuring point at cyclone outlet flue Temperature measuring point on the loop seal lift line Pressure measuring point on the loop seal lift line Temperature measuring point at loop seal inlet Pressure measuring point at loop seal inlet Pressure measuring point at loop seal compartment

Qty 2 2 2 2 4 4 2 2 2 2 2 2 4

Table 1 Measuring point description Range of Running Function measuring value (a reference) Monitor Monitor Air flow regulating Monitor Monitor Monitor Monitor Monitor Monitor Monitor Monitor Monitor Protect 420 293 2.70% 146 870 870 -200Pa -1900Pa 880 -1000Pa 870 6000Pa 42000Pa 0800 0800 020% 0800 01300 01300 4000Pa 4000Pa 01300 4000Pa 01300 010000Pa 050000Pa

Arranging location Economizer casing Economizer casing Economizer casing Air preheater casing Cyclone inlet flue Cyclone outlet flue Cyclone inlet flue Cyclone outlet flue Cyclone lower parts Cyclone lower parts At loop seal inlet At loop seal inlet Loop seal air box

Remarks

WBC
Control Principles Instruction SS505-22

Acting value <25000Pa

No. 62 63
35

Measuring name Temperature measuring point of loop seal Pressure measuring point of loop seal

Qty 2 2

Table 1 Measuring point description Range of Running Function measuring value (a reference) Monitor Monitor 870 6000Pa 01300 012000Pa

Arranging location Loop seal gradient leg Loop seal gradient leg

Remarks

WBC

Note: Other measuring points refer to arrangement drawing of measuring point and combustion system drawing.

Control Principles Instruction SS505-22