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

Set point, ysp In feedback control, the

objective is to reduce the error
signal to zero where
Input signal, ym Output signal, p
Controller
(from transmitter) (to control valve)

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


e 
t e
rr
ors
i
gna
l
s
p
yt s
etpo
i
nt

m
yt me
as
ur
edv
a
lu
eo
ft
hec
on
tr
ol
le
dva
r
ia
bl
e
(
ore
qu
iv
al
ents
ig
na
lf
ro
mt
hes
en
so
r
/t
ran
s
mit
te
r)

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)p K ce (t)
where,
Kc = proportional gain of the controller.
p = Bias (steady state) value or controller’s bias signal.
(i.e. actuating signal then e = u)
p(t) = controller output

Transfer Function
P'()
s
G
c s
() Kc
Es()
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
 t


1
p
(
t
)
pK
c

e
(
t
) 
e
I0
(t
)d
t

Where, I is the integral time constant or the reset time.

Transfer Function
P
'
(s)  1 
G
c(
s) 
E
(
s )
c
K1


s
I  

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
p
(
t
)
pK
c
 1

e(
t
)
 1
t

e
0
(t
) 
D
dt

de

dt  
Where, τD is the derivative time constant.

Transfer Function

G
(
cs
)
P
'
(
E
(
s
)
 
s)
K
c
 1

1
 1s


s
D
  

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
 Let’s 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.

Don’t 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
 540°C, 255 Ksc
568°C, 47
Ksc 492°C, 260 Ksc

FUR ROOF
457°C, 49 Ksc
I/L HDR ECO HGR O/L
HDR
HRH LINE
MS LINE
411°C, 411°C,
277Ksc 275 Ksc

SEPARATOR

S
T FINAL SH
FINAL
O RH LTRH
R
A DIV PANELS SH PLATEN
SH
G
E
T
A VERTICAL WW
N

305°C, 49 Ksc
G K ECO
JUNCTION
HDR
LPT LPT IPT
C
O HPT
N ECONOMISER
D
E
N
S
E
R
ECO I/L

FEED WATER
By BWRP
290°C, 302 KSC
S.K.MATHU SUDHANA
Executive Trainee 05 FUR LOWER HDR
FRS
COMMISSIONING NTPC SIPAT
 BOILER OPERATING PARAMETER
FD FAN 2 No’S ( AXIAL ) 11 kv / 1950 KW 228 mmwc

1732 T / Hr

PA FAN 2 No’s ( AXIAL) 11 KV / 3920 KW 884 mmwc

947 T / Hr

ID FAN 2 No’s ( AXIAL) 11 KV / 5820 KW 3020 T / Hr

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/ 277 Ksc / 412 C

TEMPERATURE

ECONOMISER INLET 304 Ksc / 270 C

MILL OPERATION 7 / 10
660MW & 500 MW PARAMETERS :

5000 MW AT BMCR
DESCRIPTION UNIT 660 MW AT BMCR

S/H STEAM FLOW T/HR 2225 1625

SH STEAM PR KG/CM2 256 178

SH STEAM TEMP 0C 540 540

RH STEAM FLOW T/HR 1742 1397.4

RH STEAM TEMP INLET 0C 299 340

RH STEAM TEMP OUTLET 0C 568 540

RH STEAM PRESS 41.9

OUTLET KG/CM2 46.61

FEED WATER TEMP 0C 289.64 255

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
STORAGE TANK
S

ECONOMISER

ECO I/L
HPH

FL
AS
H
W ZR
R T
AN
K

CONDE
NSER CEP LPH DA
 FEED WATER PATH - LOAD < 30% Back

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

ECO I/L

MIXING PIECE

CCP UG
 FEED WATER PATH – LOAD > 30% Back

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
SEPARATOR ACTUAL LEVEL
LEVEL SET POINT
FROM ULD
SEPARATOR LEVEL SETPOINT
SUB
10

LEVEL SETPOINT
8

6
PID Series1
4

2
0
0 100 200 300 400
ULD

TO BFPS
ULD 0 300
MIN. FW FLOW FW FLOW TO
SET POINT ECONOMISER

SUB
DP SET POINT
DP ACROSS CC ACROSS CC
PUMP PUMP

PID
SUB

PID
<

CC PUMP WILL TRIP IF DP

UG VALVE IS < 4.5 Kg/Sqcm
 BFP HEADER
PRESSURE
TRANSMITTERS
SEL
HIGHEST OF TDBFP HIGHEST OF MDBFP
SUCTION FLOWS SUCTION FLOWS

SUB
FG FG

PID >

FWPCV
MEASURED SEPERATOR LEVEL STORAGE TANK
OUTLET LINK SET POINT
LEVEL

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 SEPERATOR
PLATEN SH DT OUT STM TEMP OUT STM PR
BMD BOILER MASTER
DEMAND DSH SEP SEP

SEPERATOR OUTLET F2(x)

TEMP SET POINT
F1(x)
F3(x)
NOT DRY MODE
SET TO ZERO
PI
FG ∑

PI

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

A
a 30 %
b
TOTAL FW FLOW
> T2 A

FB SIGNAL
FWF F(x)

PI

TO BFPs
 DT SETPOINT IN FW LOOP BM(%) DT
30
25
0 0
DT SETPOINT

20
15 Series1
10
5
28.8 11
0
0 50 100
BOILER MASTER
43.3 28

52.1 22
 Final Control Elements In FW

Control Element Initial condition till Condition from CC

Chemical parameter Is Pump start / BLU Load > 30 %
achieved before up to Load < 30 %
CC Pump start 5 WET MODE 6 DRY MODE 7

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%

CC Pump / UG Feed water flow

valve control
-- --
Feed water FW pressure control at FW pressure Full open and
Valve ( Eq. to upstream of valve control at bypass valve opens
LLCV of St II ) upstream of valve

WR/ZR Separator Separator Hi

Level control Level
--
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

DT SETPOINT FOR FDSH

0 0
30
25 28.8 27
DT SETPOINT

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

100 7
 DIV SH PLATEN SH FINAL SH

406 451 440 486 480 540

DSH1 DSH2

15% 3%
•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
296 451 451 560

0%
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 Off

 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 Off
 All Feeders are Off
 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 Off
 Both FD Fans Off
 Unit Air Flow < 30 % TMCR
 All Feed Water Pumps Are Off 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 Input
Boiler Feed
Mode Turbine controls To Boiler To turbine
controls Forward
Controls control
Steam MW error
Throttle Pressure
BFM Pressure
MW
error
Flow (Load controller
[BLI] active)
MW error
Pressure MW error
CMC Pressure MW
error GNI O/P
(Load controller
active)
MW & PRTD
Throttle- pressure
Pressure Pressure Turbine
TFM [Manual at
(Pressure
error load set
Pressure error
controller active)
KORBA] point
Produces
Throttle- pressure UNIT
RUN steam as BM
(Pressure Capability Pressure error
BACK per unit Bypassed
controller active) Signal
capability
COORDINATED MASTER CONTROL
SCHEME
COORDINATED MASTER CONTROL
SCHEME
COORDINATED MASTER CONTROL
SCHEME
COORDINATED MASTER CONTROL
SCHEME
COORDINATED MASTER CONTROL
SCHEME
Thank You