Welcome to the presentation on Control loops

By
K.V.PRASAD,
SR.FACULTY
NTPC PMI
For
Engineers from TVNL

The Control Loops

Introduction
Furnace Press Control
Secondary Air Flow Control
Drum level control
Feed water loop
Steam Temp Control
RH Steam Temp Control
Burner Tilt Control
Fuel Flow Control
PA Header press Control
Mill Air Flow Control
Mill Air Temperature Control
HP / LP BP Controls

The Basic Control Schemes

On-off Control
Proportional Control
Proportional-Integral ( P-I ) Control
Proportional Derivative ( P-D ) Control
Proportional-Integral-Derivative ( PID ) Control
Ratio Control
Spilt Range Control
Cascade Control
Feed-forward Control
Adaptive Control
Intelligent Controls

Feedback Controllers
In feedback control, the
objective is to reduce the error
signal to zero where

e t

error signal

e(t) = ysp (t) - ym (t)

ysp t set point

ym t measured value of the controlled variable
(or equivalent signal from the sensor/transmitter)
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Proportional Control
For proportional control, the controller output is
proportional to the error signal,
p
(
t
)

K
e
(
t
)
c
where,
Kc = proportional gain of the controller.
= Bias (steady state) value or controllers bias
p signal.
(i.e. actuating signal then e = u)
p(t) = controller output
Transfer Function

P '( s )
Gc ( s )
Kc
E (s)
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Proportional -Integral (PI)

Control
The actuating signal is related to the error by
p (t ) p

Kc

1
e(t )
I

e
(
t
)
dt

Where, I is the integral time constant or the reset time.

Transfer Function

Gc

P '( s )
1
( s)
Kc 1

E ( s)

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Proportional -Integral
-Derivative (PID) Control
The actuating signal is related to the error by

1
p (t ) p K c e(t )
1

Where,

e(t ) dt
0

de

dt

is the derivative time constant.

Transfer Function

P '( s )
1
Gc ( s )
Kc 1
D s
E (s)
1s

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Controller Comparison
P - Simplest controller to tune (Kc).
- Offset with sustained disturbance or setpoint
change.
PI - More complicated to tune (Kc, I) .
- Better performance than P
- No offset
- Most popular FB controller
PID - Most complicated to tune (Kc, I, D) .
-

Better performance than PI

No offset
Derivative action may be affected by noise
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

Typical Response of Feedback

Control Systems
Consider response of a controlled system after a sustained disturbance occurs (e.g., step change in the
disturbance variable)

BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956

The Basic Control Schemes : Responses

Lets recognise these:

Roughly 75% of process control loops cause more
variability running in the automatic mode than they do
in the manual mode.
A third of them oscillate as a result of nonlinearities
such as valve dead band.
Another third oscillate because of poor controller
tuning.
The remaining loops oscillate because of deficiencies
in the control strategy.

Some simple rules of Tuning the Auto Control Loops

Increase the gain to achieve tight control and to speed up the set point
response.

Decrease the gain to provide a smoother, slower, and more stable response.

Whereas insufficient gain slows down the initial approach, inadequate reset
action slows down the final approach to set point.

If the reset action is too large (reset time too small), there is excessive
overshoot.

Some simple rules of Tuning the Auto Control Loops

If there is excessive overshoot and oscillation, decrease the reset action
(increase reset time).

For level loops with low controller gains (< 5.0), reset action must be
greatly restricted (reset time increased to 50 or more minutes) to help
mitigate nearly sustained oscillations.

Rate is primarily used in temperature loops that have narrow span

transmitters and slow scan times.

Some simple rules of Tuning the Auto Control Loops

There is noise in every process variable.

If the noise is greater than the measurement resolution limit, the loop sees it.

If it causes an output change greater than the final element or control valve
resolution limit, loop variability will be worse in auto than in manual,
particularly if there is any rate action.

Tuning the Auto Control Loops

Test new tuning settings by changing the set point in both directions.

Dont leave these new settings over night until you are sure they are
right.

Before entering new settings, ask the operator for permission to tune
the loop.

Ask the operator what the maximum allowable size of variation.

Put the controller in manual before tuning.

Feed Forward Control

Useful for processes with significant dead times.
Controlled condition is affecting processes other than that is
being controlled.
Controller is required to respond promptly but the response of
the measured value is slow.
Usually it is the derivative of the external measurement.
The Anticipatory action is added to the output of the controller.
Normal feedback control after the passing off of the transient.

Cascade Control

Cascade control is a type of control in which a secondary (slave or

inner) loop is added.
Secondary Loop gets a set point from a primary (master or outer) loop.
The secondary loop response is normally faster than (about five times)
the primary loop response.
The secondary loop can correct for upsets it can measure before they
affect the primary loop.

18

25 November 2012

19

25 November 2012

20

Obsolescence

540C, 255 Ksc

568C, 47
Ksc

492C, 260 Ksc

457C, 49 Ksc

FUR ROOF
I/L HDR

ECO HGR O/L

HDR

HRH LINE
MS LINE
411C,
277Ksc

411C,
275 Ksc

SEPARATOR

T
A
N
K

G
LPT
C
O
N
D
E
N
S
E
R

LPT

IPT

FINAL
RH
DIV PANELS SH

FINAL SH
LTRH

PLATEN
SH

VERTICAL WW
305C, 49 Ksc

S
T
O
R
A
G
E

HPT

ira
Sp

ECO
JUNCTION
HDR

ECONOMISER

lls
wa
r
at e
lw

By

ECO I/L

FEED WATER

BWRP

290C, 302 KSC

S.K.MATHU SUDHANA
Executive Trainee 05
COMMISSIONING NTPC SIPAT

FUR LOWER HDR

FRS

BOILER OPERATING PARAMETER

FD FAN

2 NoS ( AXIAL )

11 kv / 1950 KW

228 mmwc
1732 T / Hr

PA FAN

2 Nos ( AXIAL)

11 KV / 3920 KW

884 mmwc
947 T / Hr

ID FAN

2 Nos ( AXIAL)

11 KV / 5820 KW

TOTAL AIR

2535 T / Hr

SH OUT LET PRESSURE / TEMPERATURE / FLOW

256 Ksc / 540 C

2225 T / Hr

RH OUTLET PRESSURE/ TEMPERATURE / FLOW

46 Ksc / 568 C
1742 T / Hr

SEPARATOR OUT LET PRESSURE/

TEMPERATURE

277 Ksc / 412 C

3020 T / Hr

660MW & 500 MW PARAMETERS :

DESCRIPTION
S/H STEAM FLOW
SH

STEAM PR

SH STEAM TEMP

2225

1625

KG/CM2

256

178

540

540

T/HR

1742

1397.4

299

340

568

540

KG/CM2

46.61

INLET

RH STEAM TEMP OUTLET

RH STEAM PRESS
OUTLET

660 MW AT BMCR 5000 MW AT BMCR

T/HR

RH STEAM FLOW
RH STEAM TEMP

UNIT

41.9

25 November 2012

26

25 November 2012

27

25 November 2012

31

25 November 2012

32

FEED WATER PATH INITIAL STAGE

Back

VERTICAL WW

SEPARATORS

F
W
R
S

STORAGE TANK
er
at

ECONOMISER

w
l ls
a
r
i al
Sp w

W
R

FL
AS
H
T
AN
K

ECO I/L

HPH

ZR

CONDEN
SER

CEP

LPH

DA

FEED WATER PATH - LOAD < 30%

Back

VERTICAL WW
SEPARATORS
S
T
O
R
A
G
E
T
A
N
K

HPH

er
at

ECONOMISER

w
l ls
a
r
i al
Sp w

ECO I/L

MIXING PIECE

CCP

UG

Back

FEED WATER PATH LOAD > 30%

S
E
P
A
R
A
T
O
R

S
E
P
A
R
A
T
O
R

VERTICAL WW

HPH

ll
wa
r
e
t
wa
al
r
i
Sp

TO BACKPASS
CONNECTING PIPES

ECONOMISER

ECO I/L

SEPARATOR
LEVEL SET POINT
FROM ULD

ACTUAL LEVEL

SUB

PID

TO BFPS

ULD

300

MIN. FW FLOW
SET POINT

FW FLOW TO
ECONOMISER

SUB
DP SET POINT
ACROSS CC
PUMP

DP ACROSS CC
PUMP

PID

SUB

PID

<
UG VALVE

CC PUMP WILL TRIP IF DP

IS < 4.5 Kg/Sqcm

BFP HEADER
PRESSURE
TRANSMITTERS

SEL
HIGHEST OF TDBFP
SUCTION FLOWS

SUB

HIGHEST OF MDBFP
SUCTION FLOWS

FG

FG

>

PID

FWPCV

MEASURED SEPERATOR LEVEL

STORAGE TANK
OUTLET LINK
LEVEL

SET POINT

SUB
F(X)

F(X)
PID

WR

ZR

WARM UP VALVE

Wet Mode and Dry Mode of Operation

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 outlet 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

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

SEPERATOR OUT
STM TEMP

PLATEN SH DT

BMD

BOILER MASTER
DEMAND
SEPERATOR OUTLET
TEMP SET POINT

DSH

SEP

F2(x)
F1(x)

F3(x)
PI

FG

SEP

SEPERATOR OUT
STM PR

NOT DRY MODE

SET TO ZERO

PI
FF SIGNAL

ANY SCANNER FLAME (AND)

BCP OFF

0%
A
a

>

TOTAL FW FLOW

FWF

F(x)

FB SIGNAL

PI

TO BFPs

T2

30 %
A

BM(%)

DT

28.8

11

43.3

28

Final Control Elements In FW

Control Element

MDBFP
SCOOP/TDBFP
speed

CC Pump / UG
valve

Feed water
Valve ( Eq. to
LLCV of St II )

Initial condition till

Chemical parameter Is
achieved before
5
CC Pump start

Condition from CC
Pump start / BLU
up to Load < 30 %
6
WET MODE

Load > 30 %
DRY MODE

FW master in manual
control. Initial FW flow
at 200 T/Hr and
Later 600T/Hr when
WR opens to 30%

Separator
Level control

Feed water flow

control

-FW pressure control at

upstream of valve

Feed water flow

control

FW pressure
control at
upstream of valve

-Full open and

bypass valve opens

SH STM TEMP CONTROL

SH STM TEMP CONTROL

SH STM TEMP CONTROL

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

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 (SF < 25 %)

BM(%)

DT

28.8

27

43.3

21

52.1

18

70.7

DIV SH

406

PLATEN SH

451

440

FINAL SH

480

486

DSH1
15%

DSH2
3%

540

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

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

Burner Tilt for lower mills in service +20 Deg

Burner Tilt for higher mills in service -8 Deg

LTRH

FINAL RH

DSH
296

0%

451

451

560

FUEL FLOW CONTROL

PA HDR PRESS CONTROL

PA HDR PRESS CONTROL

MILL-A AIR FLOW CONTROL

MILL A AIR TEMP CONTROL

Control time scheduling of hp bypass

valve

Control time scheduling of lp bypass

valve

Calculation Of Spray Flow

Required spray flow = Steam flow x Spray water fraction

Runbacks /Rundowns/Protections
Runbacks /Rundowns
Two TDBFPs 120%
One TDBFP + One MDBFP 95% (625 MW)
One TDBFP 65% (429 MW)
One MDBFP 30% (198 MW)
Rundown if FW master is maximum and FW flow is < FW demand
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 ( 300 T/Hr)

Vertical wall tube metal temparature hi hi (4/48) (479 DEG)
MS / RH STEAM temparature hi hi 560/580 DEG 20 sec
All BFP off for 20 Sec

SLIDING PRESSURE OPERATION

PURGE CONDITIONS
No Boiler Trip Condition Exists

All System Power Supply Available

Unit Air Flow > 30 % BMCR

Nozzle Tilt Horizontal and Air Flow < 40 %

Both PA Fans Of

The Following Condition Exist At Oil Firing System

The HOTV / LOTV Should Be Closed
All Oil Nozzle Valve Closed
The Following Condition Exists at Coal Firing System
All Pulverisers are Of
All Feeders are Of
All Hot Air Gates Of Pulverisers are closed
All Flame Scanner on all elevation shows no Flame

Aux Air Damper At All Elevation should be modulating

After Purging Boiler Light Up activites are same as in 500 MW plant

MFT CONDITIONS
Both ID Fans Of
Both FD Fans Of
Unit Air Flow < 30 % TMCR
All Feed Water Pumps Are Of For More Than 20 Sec
2 / 3 Pressure Transmitter indicate the furnace pressure High for more than 8
sec
2 / 3 Pressure Transmitter indicate the furnace pressure High High
Loss Of Re-heater Protection
EPB Pressed
Economizer Inlet Flow Low For More Than 10 Sec
Furnace Vertical Wall Temperature High For more than 3 Sec
SH Pressure High On Both Side
SH Temperature High For More Than 20 Sec
RH O/L Temperature High For More Than 20 Sec
Separator Level Low-Low During Wet Mode
Separator Level High-High During Wet Mode

The Control Loops

APRDS Pressure Control

APRDS Temperature Control
Co-ordinated Master Control (CMC)

LPH 2 LEVEL CONTROL

LPH 3 LEVEL CONTROL

HPH -5A LEVEL CONTROL

HPH -5A LEVEL CONTROL

HPH -6A LEVEL CONTROL

HPH -5B LEVEL CONTROL

HPH -6B LEVEL CONTROL

HOTWELL LEVEL CONTROL

HOTWELL LEVEL CONTROL

GSC MIN FLOW CONTROL

GLAND SEAL COND PR CONTROL

Why is Deaerator Pegging Required

Why is Deaerator Pegging Required

Heat the incoming feed water to the saturation point to reduce the
solubility of entrained gases.
The gases are basically O2, CO2 and NH3 - very corrosive at
elevated temperatures.
Set of trays that separates the water into thin sheets from which the
gases can easily escape.
The gases are vented out of the deaerator to the atmosphere.
To ensure mixing & elimination of corrosive gases, the FW level &
steam pressure controls are important.

DEAERATOR PRESS CONTROL

DEAERATOR LEVEL CONTROL

DEAERATOR LEVEL CONTROL

Dosing in Condensate & Feed Water

Hydrazine is used as oxygen scavenger.
Hydrazine is one of the most costly chemical.
Hydrazine dosing done at De-aerator outlet (BFP suction)
Feed water has to be alkalized to a pH of 9 or higher, to reduce
oxidation.
Also helps in forming of a stable layer of magnetite on the water-side
surface of the boiler, protecting the material underneath from further
corrosion.
Achieved by dosing alkaline agents into the feed water, like NaOH or
volatile NH3.
Ammonia dosing done at CEP Discharge.

AMMONIA DOSING CONTROL

HYDRAZINE DOSING CONTROL

Chemical Dosing in Drum

It is the Drum which speaks in a tube type boiler!
Loose reddish powder Boiler corrosion
Loose Greyish powder Economiser / pre-boiler corrosion
Purpose is to reduce hardness and facilitate scale control.
Phosphate is a highly soluble, powder compound significantly
effective for hardness & scale control
Binds to calcium prevents scaling but forms a sludge.
Phosphate dosing done at boiler drum.

PHOSPHATE DOSING CONTROL

BURNER TILT CONTROL

BURNER TILT CONTROL

RH STM TEMP CONTROL

RH STM TEMP CONTROL

RH STM TEMP CONTROL

Why AH Cold end needs to be protected?

Boiler Flue gas contains water vapour, sulfur & other
chemicals.
Low Flue gas temp. (below dew point) at AH cold end may
result in condensation of water vapour.
Combination with sulfur forms sulfuric acid.
Results in corrosion of the cold end metal.

AH COLD END TEMP CONTROL

AH COLD END TEMP CONTROL

CBD TANK LEVEL CONTROL

ATOMISING STEAM PRESS CONTROL

HFO FLOW CONTROL

LDO FLOW CONTROL

HFO HEATER A O/L TEMP CONTROL

HFO PUMP DISCH PRESS

CONTROL

LDO PUMP DISCH PRESS CONTROL

HP BYPASS SYSTEM PRESS

CONTROL

HP BYPASS SYSTEM PRESS

CONTROL

SPRAY BLOCK VALVE LOGIC

HP BYPASS SYSTEM MISC ALARMS

HP BYPASS SYSTEM TEMP

CONTROL

HP BYPASS SYSTEM TEMP

CONTROL

AUX STEAM HDR PRESS CONTROL

AUX STEAM HDR PRESS CONTROL

HT AUX STEAM HDR TEMP CONTROL

LT AUX STEAM HDR TEMP CONTROL

Input

Boiler
controls

Turbine controls

BFM

Throttle
Pressure

MW

CMC

Pressure

MW

Mode

TFM
RUN
BACK

MW &
Pressure
[Manual at
KORBA]
Produces
steam as
per unit
capability

Feed
Forward

Input
To turbine control

Pressure
error

Steam
Flow
[BLI]

Pressure
error

MW error
GNI O/P

MW error
(Load controller
active)
MW error
(Load controller
active)

Throttle- pressure
(Pressure
controller active)

Pressure
error

PRTD
Turbine
load set
point

Pressure error

Throttle- pressure
(Pressure
controller active)

UNIT
Capability
Signal

BM
Bypassed

Pressure error

To Boiler

Controls

COORDINATED MASTER CONTROL

SCHEME

COORDINATED MASTER CONTROL

SCHEME

COORDINATED MASTER CONTROL

SCHEME

COORDINATED MASTER CONTROL

SCHEME

COORDINATED MASTER CONTROL

SCHEME

Thank You