TH 1694

A DISSERTATION REPORT ON
"^BOIUR DRUM UBVEL CaiiTROL IBT

THERMAL POWER PIAUnT
Submitted in partial fiilfiliment of the requirement for the Award of the

Degree of
MASTER OF TECHNOLOGY
IN
INSTRUMENTATION - SAÂjî.(y^
BY
, ^ ^ DHABAVATH KISHAN
Under the esteemed guidance of
Dr. ASHAVANI KUMAR

Asst. Professor
NIT Kurukshetra
&
SUBRAMANYAM CVB
NTPC Ramagundam
NATIONAL INSTITUTE OF TECHNOLOGY

(Institution of National Importance)
KURUKSHETRA
NATIONAL INSTITUTE OF TECHNOLOGY
KURUKSHETRA
DEPARTMENT OF PHYSICS
This is to certify that the project entitled "BOILER DRUM

LEVEL CONTROL IN THERMAL POWER PLANT", which is being
submitted by DHARAVATH KISHAN bearing Roll No.207511, for
fulfillment of the Master of Technology in Instrumentation, is the record for
his work carried out by him under my guidance.
Internal Supervisor External Supervisor
Dr. ASHAVANI KUMAR SUBRAHMANYAM CVB

Asst. Professor Sr. Superintendent
Dept. of Physics Control & Instrumentation Dept
NIT-Kurukshetra NTPC Ramagundam
V 4.a;.«j35rOTC.v.?.5WHAhg«ifAi
ACKNOWLEDGEMENT
I worked on this thesis for six month between January 2009 and June 2009. The thesis is
a result of support, collaboration and help from NTPC Ramagundam employees, my
professors, my family, friends and colleagues. It is my pleasure and privilege to express
my gratitude to my project guide Asst. Prof. Ashavani Kumar and Subrahmanyam CVB,
Sr.Superintendent, NTPC Ramagundam, whose support guidance and continued
enthusiasm made this work possible. I am thankful to them for the patience and care he
has shown, the valuable time they has spent on discussions during this project work and
for providing me directions whenever it was needed.
I am also very grateful to CVB Subrahmanyam, Sr. Supt (0«&M) and Meghanathan,
Supt (O&M) and M. Prasad, Dy. Supt (O&M) for giving their valuable comments during
the evaluation of the project. Especially, Asst, Prof, Ashavani Kumar, Dept of Physics
was very kind and friendly.
I thank Dr. S.K. Mahna, Professor & Chairman, and Dept of Physics for giving several
technical inputs, suggestions and guidance which helped me during 6 months.
I am grateful to my classmates for their help and cooperation. Especially, I would like to
thank my friends A. Suresh and P. Venkata Rajesh for his continuous help during this
project. Helping others is at the top of his list of priorities. I thank my friends K. Suresh
Babu, K. Rajendra for their help. At the end, I thank my parents and family members for
their love and support.
o
Place: Kurukshetra Dharavath Kishan
Date: 2.1 [7 1 ^ 0 ^
CONTENTS
ABSTRACT
LIST OF FIGURES
LIST OF ABBREVIATIONS
S No Chapters Page No
1 Introduction 2
1.1.1 Drum Level 3
1.1.2 MS Temperature and Water Level System 5
1.1.3 Control of Level with PID Controller 6
1.2 Description 7
1.2.1 Block Diagram 7
1.2.2 BFPs Control 9
1.2.3 Level Transmitters 10
1.2.4 Differential Transmitters 11
1.2.5 Flow Transmitters 12
2 Process and Description of Logic Diagrams 14 ,

2.1.1 Logic Diagrams 15
2.1.2 Symbols Used 14
2.1.3 Boiler Parameters Measurement and Control 16
2.1.4 BFPs Control 17
2.1.5 Level Transmitters 19
2.1.6 HPBP and MS Temperature 21
2.1.7 Feed water 22
2.1.8 TDBFP- A&B and MDBFP 23
2.2 Description of Logic Diagrams 24
Boiler Drum Level Control in Thermal Power Plant

Boiler & Feed Pump System 28
3.1 Boiler 29
3.1.1 Firetube Boiler 30
3.1.2 Watertube Boiler 31
3.1.3 Description of Boilers 32
3.1.4 Parameters of Boilers 34
3.2 High Pressure Bypass System (HPBP) 38
3.2.1 Arrangement of HPBP 38
3.2.2 Application 39
3.3 Turbines 40
3.3.1 Types of Turbines 41
3.4 Generators 42
3.4.1 Operation 43
3.4.2 Condenser 45
3.4.3 Condenser Extraction Pump (CEP) 47
3.5 Pressure Heaters 49
3.5.1 Low Pressure Heaters (LPH) 49
3.5.2 High Pressure Heaters (HPH) 49
3.5.3 Extraction Steam System for Heaters 49
3.5.4 HP Heaters 51
3.5.5 Specification of HP Heaters 52
3.6 Deaerator 53
3.7 Feed Piimp System 54
3.7.1 Function of Feed Pump 54
3.7.2 Boiler Feed Pumps 55
3.7.3 TDBFP 57
3.7.4 MDBFP 57
3.7.5 Description of TDBFP 57
3.7.6 Philosophy TDBFP 60
3.7.7 Advantages TDBFP over MDBFP 61
3.7.8 Specification ofTDBFP& MDBFP 61

PID Controller & MaxDNA 62
4.1 PID Controller 63
4.1.1 Function of PID Controller 63
4.1.2 Process of Controlling 64
4.1.3 Details of Drum Level Control to
Controller Action 67
4.2 MaxDNA 70
4.2.1 MaxDNA System Architecture 70
4.2.2 MaxDNA System with Thermal Station 71
4.2.3 MaxSTATION 72
4.2.4 MaxSTORIAN 72
4.2.5 MaxLINK 73
4.2.6 MaxDNA DPU 73
4.2.7 Remote Processing Unit (RPU) 74
Results 75
5.1.1 Waveforms 76
5.1.2 Output Data 76
5.2 Conclusion 80
References 81

LIST OF FIGURES
Fig 1.1 Drum Level Control 4

Fig 1.2(a) Control of Level with PID Controller 6
Fig 1.2(b) Block Diagram 8
Fig 1.3 Levels Transmitters to Drum 11
Fig 1.4 Differential Pressure Transmitters 12
Fig 1.5 (a) Orifice flow meter 12
Fig 1.5 (b) Venturi meter 13
Fig 2.1 Symbols shown in logic diagram 15
Fig 2.2 Boiler Parameters Measurements and Control 16
Fig 2.3 Speed control of Boiler Feed Pumps 17
Fig 2.4 BFPs and BFP discharge header 18
Fig 2.5 Level Transmitters 19
Fig 2.6 Main steam Pressure Reducing Desuperheating steam 20
Fig 2.7 HPBP to MS Temperature 21
Fig 2.8 Feed water system 22
Fig 2.9 shows TDBFP-A«&B and MDBFP 23
Fig 3.1 Schematic Diagram of Boiler 29
Fig 3.2 Firetube type Boiler 30
Fig 3.3 Watertube type Boiler 31
Fig 3.4 Boiler Parameters 34
Fig 3.5 Boiler Drum 35
Fig 3.6 Economizer 36
Fig 3.7 HPBP System 38
Fig 3.8 Logic Diagram of HPBP system 39
Fig 3.9 (a) Turbines and Condenser overview 40
Fig 3.9 (b) Turbine Blades 41
Fig 3.10. Overview of LP turbine and Generator 42
Fig 3.11 Condensate System 46

F ig 3.12 Condenser Extraction Pump 47
Fig 3.13 Extraction Steam System for Heaters 50
Fig 3.14 High Pressure Heaters 51
Fig 3.15 Deaerator connected with BFPs 53
Fig 3.16 Boiler Circulation Pumps 54
Fig 3.17 Boiler Feed pumps 56
Fig 3.18 Structure of TDBFP 58
Fig 3.19 TDBFP-B Control 59
Fig 3.20 Structure of MDBFP 60
Fig 4.1 PID Controller action 63
Fig 4.2 Boiler System connected sensors with PID Controller 65
Fig 4.3(a) Drum Level Control parameters corresponding PID Control action 67
Fig 4.3(b) Drum Level Control parameters corresponding PID Control action 68
Fig 4.4 Time Response of drum level control 69
Fig 4.5 Time Response of Steam Temperature control 69
Fig 4.6 MaxDNA architecture 70
Fig 4.7 MaxDNA System with'Power Station 71
Fig 4.8 MaxDNA DPU Front Panel 74
Fig 4.9(a) Output Waveform When the Plant is Running & REMOTE 76
Fig 4.9(b) Output Waveform When the Plant is running in Normal 77
Fig 4.9(c) Output Waveform When the Plant is Running & AUTO 78
Fig 4.9(d) Output Waveform When the Plant is TRIPPED 79

LIST OF ABBREVIATIONS
Acronym Expansion of acronym
MS Main Steam
BFP Boiler Fieed Pump
HPBP High Pressure Bypass
PRDS Pressure Reducing Desuperheating Steam
FW Feed water Flow
TDBFP Turbine Driven Boiler Feed Pump
MDBFP Motor Driven Boiler Feed Pump
FCV Flow Control Valve
DEA Deaerator
HPT High Pressure Turbine
IPT Intermediate Pressure Turbine
LPT Low Pressure Turbine
CEP Condenser Extraction Pump
LPH Low Pressure Heaters
HPH High Pressure Heaters
PID Proportional + Integral + Derivative
MaxDNA METSO AUTOMATION MAX CONTROL (MAMC)
DCS Distributed Control System
DPU Distributed Processing Unit
RPU Remote Processing Unit

ABSTRACT
The objective of the present work is to maintain the boiler drum level at normal water
level at all loads. Boiler drum level is one of the important parameter in a Power Plant
which is to be controlled at optimum level for the continuous production of electricity. If
the water level in the drum is not controlled, there is a probability of underflow or
overflow of water in the drum. Boiler will be tripled automatically through a protection
system, but if the drum level goes below the predefined set value, there is a chance of
starvation of boiler tubes and if level goes than high set value water may enter into the
turbine. Some times it may result in uncontrollable damaged of the turbines and the
equipment connect to them, so it has to be controlled efficiently. In the view of its
importance, a study project about Boiler Drum Level Control in a 500MW unit has been
taken up.
In order to prevent sudden change due to drum water level swell and shrink on
load change, a three element control loop has been used. That is 3-element is feedwater
fiow (FW), steam flow (SF) and actual drum level (DL). An error is generated between
actual drum levels measured signal, stem flow, feedwater flow and drum level set points
shall have PID action in the drum level controller. A predefined water level is set for a
particular drum; the controller produces appropriate controller output based on the error
generated from the three measured values and its set point. This controller output will be
the desired speed signal for the individual Turbine Driven Boiler Feed Pumps (TDBFP)
speed control system. When the drum level actually deviates far its normal level on either
side. Generally Coal-fired boilers are used for the combustion process with Coal as the
main fuel along with the Air.
The water level of the drum is maintained at constant level by the speed of
Turbine Driven BFPs and hence the control, separate auto/manual station is provided for
each feed pump speed regulating device. Boiler Drum Level Control based on the set
values of low level and high-level supervision properly for performance improvement of
steam temperature and efficiency of boilers.
Boiler Drum Level Control in Thermal Power Plant 1

a o H)cn
B
INTRODUCTION

1.1 INTRODUCTION:
Ramagundam Super Thermal Power Station(2600 MW- ISO 9001, ISO

14001,OHSAS 18001,SA 8000 Certified Station), one of the biggest thermal power
stations in India, is a coal based power station situated at Ramagundam, Andhra Pradesh,
and the station started power generation in 1983 [1]. The station generates about 2600
MW of power. NTPC Ramagundam is the first thermal station in India to get ISO 14001
certificate.
Boiler steam drum water level is one of the most important power plant
parameters to control. If the level is too low, boiler tubes will be damaged by
overheating. If the level is too high, the superheater tubes and the turbine may be
damaged by moisture or water treatment chemical carryover. As boiler operating
pressures and boiler drum wall thickness have increased, many boilers have become
smaller. This reduced boiler drum volume demands even more accurate level control.
1.1.1 Drum Level Control:
The main objective of this control is to maintain the drum level at normal water at
all loads. At the lower loads the start up feed control valve is used and at higher loads,
speed control of boiler feed pumps will be used. Drum level is measured by three level
transmitters on left and right side respectively through temperature compensated constant
head unit. Mean value signal of level is compensated for pressure on left and right side
respectively. The minimum value of the left and right drum level is taken for control.
Internal diagram of drum level control in the power plant as shown in fig 1.1.

DRUMLE¥Ei;CONTRDL' .'It... . ^ . , _ „ ^
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Fig 1.1 Drum Level Control
A Feedwater control system employs a three element control scheme employing three
differential pressure type level transmitters. The use of a median select or averaging of
the transmitter outputs for control should be determined based on the requirements.
In order to prevent sudden response due to drum level water low load and high
load on load change, a derivative signal of actual drum pressure compensates the three
element error signal. The error signal produced between drum levels measured signal and
drum level set point shall have PID action in the drum level controller. This will be added
with steam flow signal which is the feedwater flow demand signal. This will be compared
with the feedwater flow in the feedwater controller. Deviation if any will have a PID
action in the feedwater controller. This controller output will be the desired signal for the
boiler BFP speed control or Feed Control Valve for start up. The change over from low
load to full load is automatic.

Three element errors are computed as under:
L = LS-LM-K2 (F-S-Kj)
LS = Set Level
LM = Measured level
F = Feedwater flow
S = Steam flow
Ki - Blow down constant
K2 = Constant dependent on the degree of correction to be contributed by
Feedwater flow/steam flow error.
THE BOILER system in a thermal power plant consists mainly of a steam-water system
and combustion system, which produce a high-pressure superheated steam to drive a
generator in order to produce power. The superheated steam temperature control and the
separator water level control of a steam water system are very important to guarantee the
operation safety and to improve economic benefits of the power plant.
1.1.2 MAIN STEAM TEMPERATURE AND WATER LEVEL SYSTEM:
The investigated boiler of a 500MW power unit is a compound circulatory tower

boiler with low circulation ratio, which can produce 1590 tons of steam per hour at a
maximum continuous rating [12]. The rated superheated steam pressure and temperature
are 172 Kg/cm^ and 545 °C, respectively. In the boiler's steam-water system, the water is
taken from the deaerator by using three motor-driven pumps. It goes through a high-
pressure heater, feed-water valve, economizer, mixer, recycling pump, water wall, and
arrives at the steam separator. The water in the separator circulates naturally through the
water wall and mixer by recycling pumps, which absorbs radiating energy from the
furnace continuously. The saturated steam produced through the above process flows out
of the top of the Drum (separator), is reheated by the primary super heater, by the
secondary super heater, and the third super heater in sequence. The primary spraying and

the secondary spraying are to maintain the constant steam temperature, if the coal
variations occur in the furnace.
1.1.3 Control of Level with PID Controller:
Controlling the boiler drum level should control the speed of the Boiler Feed
Pumps according to the PID Controller action. The fig 1.2(a) shows control of boiler
drum level with PID Controller.
setpoint of
wafer level
sp pi^JX
— . , . Steam
Trt?^ Separator r>
Steam to turbine
Fig 1.2 (a) Control of Level with PID Controller
The following two key points:
• The actual water level (WL) of the separator and its set point value (SP) of the
water level.
• The main steam flow Fm, the feed-water flow /y.
The water level of the drum also affects the final steam temperature,
proper water control is very necessary in the drum. The water level process is usually
controlled with PID Controllers as shown in Figure 1.2(a)

1.2 DESCRIPTION OF DRUM LEVEL CONTROL:
The main control task is to achieve response of drum level to steam temperature
and steam pressure. Primary manipulated variables are: Main Steam Flow (MSF),
feedwater flow (FWF), spray flow (SF), Pressure Reducing Desuperheating Steam
(PRDS) flow, and High Pressure By Pass (HPBP) flow.
In addition, the mainly controlled variables are: feedwater flow (FWF), main
steam pressure (MSP), and main steam temperature (MST), Boiler/Main drum level
(BDL/MDL), Generally, the coal-fired power plant is a MIMO system [18], in which
many control loops are equipped to accomplish the above task and maintain normal
operation of the boiler.
1.2.1 BLOCK DIAGRAM OF DRUM LEVEL CONTROL:
Figure 1.2(b) shows a block diagram of the typical boiler drum level control process.
Pulverized coal with pre-heated air is fed to furnace to be combusted [2]. Main Feed
Water Flow (MFWF) is the normal water is pressurized by a steam driven boiler feed
pump and passes through a number of superheater Steam generated in the boilers
separated in the drum from where it flows through the super-heaters on to the high
pressure turbine, which results reduces the steam pressure and it then reenters the boiler
to the reheated where its energy level is increased. It then flows through the intermediate
and low pressure turbine to the condenser through condenser extraction pump (CEP).The
steam condensed may be recovered to provide a source of pure feed water to the boiler
and reduce the water softening capacity to a considerable extent, this water is goes to
Deaerator (DEA) tank and it is connected Boiler Feed Pumps (BFP) and Feed Control
Valves (FCV), BFP may be turbine driven or motor driven. This BFPs connected with 3-
element control action PID controller for control the speed of boiler feed pumps.

The block diagram of Boiler Drum Level control is shown in fig 1.2(b)
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Fig 1.2(b) Block Diagram

The process of flow considered as follows:
Total Feed Water Flow = Feed Water flow + Spray Flow

Total Steam Flow = Steam Flow + PRDS Flow + HPBP Flow
• Feed Water Flow: regulates boiler feedwater flow to maintain drum level at set
point.
• Spray Flow: The amount of water required to control the steam temperature
exiting the superheater. The water source for the control the steam temperature
generally after the economizer section to main feed pump of the boiler drum.
• Steam Flow: Normal steam coming out of the boiler drum.
• PRDS Flow: Pressure Reducing Desuperheating Steam (PRDS) Flow is added
with steam flow for required to reduce the steam pressure.
• HPBP Flow: By High Pressure By Pass flow (HPBP) bypassing steam to the
condenser through a turbine bypass valve and/or the turbine above seat drains
while regulating the heat input, better matching of steam temperature to turbine
metal temperature is achieved prior to rolling the turbine.
1.2.2 BOILER FEED PUMPS (BFPs) SPEED CONTROL:
In a power plant, the boiler water is circulated in a closed loop by a feed pump driven
either by electric motor or steam turbine. The pump takes the water from the deaerator or
high pressure heaters and boosts the pressure to the system. Feedwater is taken from the
deaerator by the Boiler Feed Pumps and sent through the high pressure heaters, the
economizer, and finally into the boiler drum.
The Boiler feed Pumps, which are generally, rotate with constant speed and
constant outlet pressure, or steam driven with variable output. The water is taken from the
Deaerator (DEA) into the boiler feed pump and the pressure is raised to boiler operating
pressure. At start-up and low loads, the pumping load is small and the pump outlet

pressure is high and the drum pressure is not built up yet. In this case, there is a need for
control the speed of boiler feed pump and used to proportional integral derivative (PID)
action and the flow capacity is very low.
As the plant load increases, drum pressure increases and flow rate increases. The
pump cannot maintain the same pressure head at these higher flows. The result is lower
inlet pressure to the valve and high back pressure on the valve. These higher flows with
lower pressure drops create a need for control the speed of boiler feed pump and used to
proportional integral derivative (PID) action and the flow capacity is very high.
The control of feed water coming from deaerator goes to Economizer. The economizer is
a feed water heater, deriving heat from the flue gases. The Economizer depends on the
total gain in efficiency and also depends on the flue gas temperature leaving the boiler
and the feed water inlet temperature.
1.2.4 Level Transmission Calibration:

• Fluctuating water level or changing rate of water inflow and steam outflow can
cause measurement errors.
• Thermodynamics of pressure and temperature, geometry of the steam drum, and
equation of continuity define transmitter calibration.
• Check the zero elevation and span against transmitter specifications to ensure
selected transmitter can be calibrated to required values.
Application of Level Transmitters:

Steam Drum Level is both a critical and difficult measurement to make [3].
Control of the water level in the drum must be precise. A water level that is too high can
result in water carryover into the steam piping. A level that is too low can expose the
generating tubes (down comers), preventing the water in the drum from cooling the
furnace tubes, possibly damaging them. Several factors make this measurement difficult
to obtain. The steam drum itself may not be perfectly level, and even at steady state
conditions, considerable turbulence in the drum can cause the level to fluctuate. In
addition, a changing rate of water inflow and steam outflow adds to the potential for

measurement error. The level transmitters connected for measurement of level at the
drum as shown in fig 1.3
n C«»(t*n«ing Pel
r
_L
Transmitter
-^ H t r
Fig 1.3 Levels Transmitters to Drum
Measurement of boiler steam drum level using a differential pressure transmitter must
take into account certain physical properties of the fluid.
> The Steam drum contains a two-phase mixture of water and steam at saturation
conditions.
> The densities of water and steam vary with saturation temperature or pressure.
> The density of saturated steam above water must be considered, as well as the
density of saturated water in the drum.
1.2.5 Differential Pressure Transmitters:
The most popular device for level monitoring on the boiler drum is the
Differential Pressure transmitter [7]. This device infers the level of the water within the
drum by comparing the head pressure generated by the water in the drum to a reference
level. Typically this reference.is derived from a chamber attached to the drum and filled
with condenser derived from the sub cooling of steam. Generally used Differential
Pressure transmitters at drum as shown in fig 1.4

Fig 1.4 Differential Pressure Transmitters
Connections are made from this reference and from the drum itself to the high and
low inputs of the level transmitter. It is important that the two inputs to the transmitter be
kept as close together in temperature as possible to prevent errors resulting from differing
SG resulting from temperature differences in the two sampling legs and erroneously
interpreting this to be a level difference.
1.2.6 Flow Transmitters:

a) Orifice meter:
Flow sensors depends on the pressure drop or head occurring as a fluid flows
through pipes [7]. The relationship between flow rate and pressure difference is
determined by the Bernoulli equation, assuming that changes in elevation, work and heat
transfer are negligible. The orifice flow meter shown in the figl.5 (a)
Fig 1.5 (a) Orifice flow meter

Bernoulli equation [4] for flow rate is given by
2(i}-i'3)
F,=AV,=C^TA,
Fi = Flow Rate
Ai, A3 = area of upward stream and down ward stream
Vi = Velocity of up ward fluid
Pi,P3 = Pressure difference
Y= Young's modulus
Cmeter= Discharge coefficient
p = Density
b) Venturi meter: The venturi tube shown in Figure is similar to an orifice meter, but it
is designed to nearly eliminate boundary layer separation, and thus form drag. The
change in cross-sectional area in the venturi tube causes a pressure change between the
convergent section and the throat, and the flow rate can be determined from this pressure
drop. Although more expensive that an orifice plate; the venturi tube introduces
substantially lower non-recoverable pressure drops. Venture type of flow meter as shown
in fig 1.5(b)
Upstream pressure throat position down pressure
Fig 1.5 (b) Venturi meter

"U" lO
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PROCli:SIS& DESCRIPTION
OF LOGIC DIAGRAMS

2.1.1 LOGIC DIAGRAMS:
In the NTPC Ramagundam, for control the parameter "Boiler Drum Level
Control" the plant was designed by using Logic diagrams [8]. The block diagram is
designed from the logic diagrams and is shown in figures given belowfig2.1 tofig2.9
2.1.2 LEGENDS:
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DRUJv« LEVEL CONTROL
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2.1.3 BOILER PARAMETERS MEASUREMENT AND CONTROL:
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Fig 2.2 Boiler Parameters Measurements and Control

2.1.4 BFPs CONTROL:
t 'NOTES 5~
REL TO
01 WHEN THE MD8FP (S OH STANDBY AND THE FRM APS DRIVE T!Q MAX
MOTOR IS OFF THE SCOOP SHALL FOLtW THE
DUiMD OF THE MASTER CONTBOLIER REL TO AUTO m oLcs mom.
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02 WHEN THE EHG OF THE RESPECTiVE TDBFP's @>
ARE SELECTED FOR LOWL OPERATION AND MDErP IS
ON MANUAL & MASTER CONTROLLER fS iN MANUAL. UCiJAPIOI
M / ^ r g R . A / W STATION SHALL TRACK THE T08FP BR MplFP-C
M08FP WHICH EVER IS PUT INTO AUTO FIRST
NATIONAL THERMAL. POWER CORPORATION- 'Lfp

RAMAGUNDAM SfPP, STAGE-fll., (»x500 *^<yii')
SHNo: 19
ANALOG CONTROL SCHEMES
DRUM LEVEL CONTROt
Fig 2.3 Speed control of Boiler Feed Pumps

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15.11FR SH55 2j FR SH.25
FHMSHTI? FRM SHTJ9

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SPEED spceo SPEED•
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NATIONAL THERMAUPOWeR COKPQMmm'ttO

SHNo:20
PRU¥ LEVEL CONTROi.
Fig 2.4 BFPs and BFP discharge header

2.1.5 DRUM LEVEL TRANSMITTERS:
'it|@^ ."•• DRUM L V t UEFT ORUM PRCSS DRUM l ^ E L RIGHT
KAOOt
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MADOl HWJOl
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ows- ows ows- OWS ows- ows:
«tFr WSAVS TX
'"•—bwsAvs g~L^^—lyfis/iys
! ' • : • • ' • '
U^j *.TO Ol.CS_

isrrf (RH PROT)
>WMA (0RG.NOJ04Z)
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ows >|i;^<H'^S""", ., wnm* -—SldHSfEn. I.VM OWS
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>S80mm <(-)375mm
TO fSSS •.. UVM — TO FSSS
Pf CONTACT
(2 OUTPUTS EACH
THROUGH SEPRATE
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HM
m'©- r PF CONTACT
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NATIONAt THERMAL POWER CORPORATtOM i f O

RAMAGUlJOAM STPP. STAGE-iH. (VKSOQ Mtf)
SHNo:21
DRUM LEVgL CONTRO'.
Fig 2.5 Level Transmitters

MS TO PROS:
^1- MS t o PROS "

• pST WRST STAGE FLOW •^v^.-. .„•=_' • PRESS TEMP
* 4 ^f
'< i MAA5D MAA90
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NATIONAL THERMAL POWER CORPORATION LTD
fmmumm STPP. STAGE-HJ,-îjnaoo ^ ' SHNo: 22
DRU*A tEVCL CONTROL
2.6 Fig shows Main steam Pressure Reducing Desuperheating steam

2.1.6 HPBP AND MS TEMPERATURE:
MS TEMP STEAM FtOW TO HPBP2

STEAM FLOW MPBPI
, ft'
LB*01
CTtOS
• V,; f
OWS ows-
s4,__"*'—jws/t^ \ SEL -—pwJAvs}
— ows-
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ows-
MS PRESS • -%
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ows- •ows
TX -t)WS/LVS|
SEL...
OWS-
f^
NATIONAL THERMAL POWER CORPORATION LTD
SHNo:ii
DRUM LEVEL COWTSOL
Fig 2.7 HPBP to MS Temperature

2.1.7 FEED WATER:
rCEO WATER
TCMP
0 U04O
(J)
CTtOI CTIOZ
OWS- •ov»s
-4wre/LVS
•ows ows-»
SH SPRAY ( L ) SM SPRAt (R)

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ows-
NATIONAL THERMAL POWER CORPORATION LTJD

RAMAOUNDAM STPP, STAGE-!!«. ( I H S O O MW)
SHNo:24
ORUM LEVEL CONTR'u.
Fig 2.8 Feed water system

2.1.8 TDBFP- A&B AND MDBFP:
T O B f P - A SUCTION TO9rP-B SUCTION
rwM ItUP PLOW
•• -till Icf^'Oi
ows OWS
OW9-
UOBfP SUCTION
if-
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NATIONAU THERMAl POWER CORPORATION iM

nmAGmam STPP, siASE-nt, (ixsoo MW)
SHNo:25
ANALOG CONTROL SCHEWES^
DRUM LEVEL CONTROL
Fig 2.9 shows TDBFP- A&B and MDBFP

2.2 DESCRIPTION OF LOGIC DIAGRAMS:
Drum Level Measurement and Control:
Boiler is important part in the large scale thermal power plant; drum is placed at
the top of the boiler. In order to prevent sudden change due to drum water level swell and
shrink on load change, a three element control has been used. That is 3-elements are
feedwater flow (FW), main steam flow (SF) and actual drum level (DL). For the level
measurement in the drum taken three level transmitters for control on left and right side
of the drum through temperature compensated constant unit head. Similarly mean value
signal of level is compensated for three pressure transmitter on left and right side
respectively.
Only one transmitter among three transmitters placed on left side of the drum is
selected from operator work station (OWS) and similarly for the drum level measurement
on right side. Drum pressure is one of the factor affecting total feed water flow.
Drum level on left and right transmitters required some correction with a
correction factor f(x), level of drum having level recording and ranges changes drum
level gives to alarm sound and human being controlled depend on the levels of drum
during normal and emergency process. Average level takes from left and right side for
reliability. Limit value monitor (LVM) is checked if level is high level or low level is
indicated by indicator on the LCD screen.
TOTAL MAIN STEAM FLOW:
Total steam flow is the added main steam flow, pressure reducing desuperheating
steam (PRDS) flow and high pressure bypass (HPBP) flow.
Main steam flow means coming steam from boiler drum to PRDS flow, where
flow transmitters, pressure transmitters and temperature element added and corrected
with correction factor. Steam first stage means out come of boiler steam measurement

with the three pressure transmitter and selecting minimum value goes to function for
correction factor affected with main steam temperature.
The total steam flow = Main steam flow + PROS flow + HPBP flow
PRDS FLOW:
Out of the boiler with high steam temperature and pressure high with water
molecule, where is required to reduce the steam pressure uses PRDS added some
auxiliary steam passes to high pressure turbine (HPT).
HPBP FLOW:
The HP BYPASS 1&2 system operation and loading independent of the turbine. HPBP
allows quick rising of the steam parameters from boiler drum to a turbine for rolling
during startup, it may damaged. So Steam bypassed from steam line to cold reheat line
through HP BYPASS.
HPBP 1 & 2 are flow transmitted corrected and selected minimum value with operator
work station (OWS) or limit value selector (LVS) correction with function f(x) , main
steam temperature and pressure selected with OWS. HPBP 1 & 2 is added and sends to
the Reheater with operator work station.
TOTAL FEED WATER FLOW:
Total feed water flow is the feed water flow and super heater spray flow left and right.
Feed water coming from deaerator through BFPs through flow transmitted corrected with
function generator f(x) and one of the best value is selected among three parameters and
water temperature also should maintain some temperature passing to function generator
f(x) with spray flow left and right side on boiler drum.

DIFFERENTIAL PRESSURE ACROSS FCS:
Differential pressure transmitted across flow control section (FCS) selected with
operator work station (OWS) and subtracted from set point (SP), output of the subtractor
from the BFPs discharge pressure selected maximum value.
BOILER FEED PUMPS MEASURED SND CONTROL:
Boiler feed pumps are two types TDBFP-A & B and MDBFP. TDBFP-A having
two flow transmitters and temperature transmitter, selecting one transmitted with
operated work station (OWS) corrected with function generator f(x). Similarly TDBFP-B
pump measured flow like TDBFP-A and MDBFP suction flow.
TDBFP-A & B can capable of 50% that is two pumps will always in service.
From TDBFP-A and TDBFP-B flow selected, maximum flow value and function
generator f(x) corrected flow and MDBFP is always in standby position. Maximum value
selected between maximum of TDBFP value and MDBFP subtracted from BFP discharge
header pressure.
OPERATION:
Drum level measured with transmitted and subtracted from set point (SP), the
output of the error, main steam flow and total feed water flow summing it may have
chemical removing from blow down connected to muhiplier with the constant value. This
output is subtracted from drum pressure and output value is summing with the error
output with operated work station (OWS).
Main steam is totally depends on the drum level, the valve FD16 open or not goes
to super heaters (SH), output of the super heater passes to PID controller. The output of
the error is shown in the indicator on LCD screen. Its control is auto or manual position
depending on the load of the-drum by the operator work station (OWS) or large video

screen (LVS). This load control depends on the flow control depends on the flow control
valve closed or open.
Maximum valve is selected from differential pressure (DP) mode, feed water
mode (FW) and boiler feed pumps (BFP).
SPEED OF BFPs CONTROLLING:
Maximum value from DP mode, FW mode and BFPs is selected and passes to
PID controlled, when BFPs are in auto/remote position, changes according to its load.
TDBFP-A & B ON and Remote position which two pumps always in service and BFP-C
is in ON and Auto position.
If any one of the TDBFP not working total load can flow to another TDBFP.
TDBFP-A is in on and remote position, TDBFP-A is subtracted from BFP discharge
header pressure, output from the error the flow signal passes to PID Controller enabled
and closed flow control valves, automatically controlled the speed of the TDBFP-A, so
minimum value selected from TDBFP-A. Similarly control the speed of TDBFP-B is also
same as TDBFP-A.
Any problem exist in the TDBFPs or at the starting time of the boiler MDBFP is
used , this MDBFP is driven with electric power, which is always in on and auto position
to PID Controlled enabled and control the speed of MDBFP.

BOILER
Vlim PUMP SYSTEM

3.1 BOILER:
A boiler is a closed vessel in which water or other fluid is heated under pressure
[5]. The steam or hot fluid is then circulated out of the boiler for use in various process or
heating applications. Boiler is a main part of the Thermal Power Plant. The function of
the Boiler is to generate steam.
> To generate heat by combustion. To transmit energy transfer to the fluid

being heated.
> The efficiency of heat generation is known as the combustion efficiency,
efficiency of the heat transfer process is known as the transmission
efficiency.
Generally in large scale thermal power plant used coal fired boiler is shown in
fig3.1 [5].
*5=
QFftfrgwJMfrf PKiw(
^^
WstarwaJl
Hsatem
Fig 3.1 Schematic Diagram of Boiler

In the furnace combustion of fuel takes place and from heat passes in the boiler. The
furnace taken coal mill, oil from oil gun and air from FD fans respectively for the process
of combustion. Steam parameters coming out of the boiler:
> Main Steam flow : 670 tph

> Main Steam pressure -157Kg/cm^
> Main Steam temperature - 540 ^C
> Reheat Steam flow -580 tph
> Reheat Steam temperature -540''C
Boilers types:
There are two general types of boilers
1. Firetube boilers
2. Watertube boilers.
3.1.1 FIRETUBE BOILER:
Firetube boilers used in the largest share of small to medium sized industrial units.
In fired tube boilers the flue gas products of combustion flow through boiler tubes
surrounded by water. Steam is generated by heat transferred through the walls of the
tubes to the surrounding water. The Firetube type of boiler is shown in fig 3.2
Exliaust .
1 I Stemn
. Combustion
v////////////////mc\
I Water
Fig 3.2 Firetube type Boiler

The flue gases are cooled as they through the tubes, transferring their heat to the water,
the cooler the flue gas, the greater the amount of heat transferred. Cooling of the flue gas
is a function of heat conductivity of the tubes and its surface, the temperature difference
between the flue gases and the water in the boiler. The heat transfer area, the time of
contact between the flue gases .and boiler tube surface, and other factors.
Firetube boilers are used spherical or cylindrical pressure vessel mounted over the
fire with flame and hot gases around the boiler shell. This obsolete approached has been
improved by installing longitudinal tubes in the pressure vessel and passing flue gases
through the tubes. This increase the heat transfer area and improves the heat transfer
coefficient.
3.1.2 WATERTUBE BOILER:
As the name implies, water circulates within the tubes of a watertube boiler. The
watertube type boiler is shown in fig 3.3. The tubes one often connected between two or
more cylindrical drums. The higher drum the steam drum, is maintained approximately
half full of water. The lower drum is fulled with water completely and is the low point of
the boilers. Boiler can be drawn off the bottom of this lower drum commonly known as
mud drum.
Steam T
Boiler diiun
Feed piunp
Heat Eisei Douit comers
Lower or Mud dirun
Fig 3.3 Watertube type Boiler

Watertube boilers can be easily designed for greatest or lesser furnace volume using the
some boiler convection heating surface; watertube boilers are particularly applicable for a
full range of sizes for pressure from 50 psig to 5000 psig. The pressure available
minimum size of industrial watertube boilers is approximately 20,000 to 25,0001bs/hr of
steam- equalent to 600 to 750 BoHP (Boiler Horse Power) many water tubes boilers
operating are in the 250 to 300 BoHP size range.
3.1.3 BOILER DESCRIPTION:
Design data:
Thermax Babcock «& Wilcox limited have carried out CA & RLA study of unit no. 7
(AP-2115) at Ramagundam Super Thermal Power Station [6].
Design condition:
> Boiler capacity 1725 TPH (tones per hour)

> Boiler design pressure 210kg/cm^
> Final steam outlet temperature 540 °C
> Feed water temperature at
Economizer inlet 256 °C
Coal:
Weight of the fuel fired design coal : 367 TPH
Typical analysis: FC 25%, VM 19%, Moisture 12%, ASH 44%.
Furnace:
Type : controlled circulation
Width : 18.034 m
Depth :15.289 m

Height : 62.456 m from furnace
Volume : 14820 m^
Tube material :SA210GrC
Tube size : 5100x5.6 Thick (mm)
Her Drum:
Material specification : SA-299
Design pressure 204 Kg/cm^
Design metal temperature : 366 °C
Located at : 60570 mm
Length : 22070 mm
Inside dia 1778 mm
Thickness used for dished ends : 152.4 mm
Shroud material : carbon steel
Efficiency of Boilers:
Two methods of calculating the efficiency of a boiler:

1. Input/Output or Direct method
2. Heat loss or Indirect method
1. Direct method:
Direct method depends on the measurement of fuel, steam and feed water flow and heat
content of each.
Heat added to Incoming Feedwater

Boiler efficiency = .
Heat Input (fuel) + Heat Input (Combustion Air)
Direct method has a loss that is called Slowdown loss.

2. Indirect method:
In this method, the percentage of each of the major losses is determined. To their
total, a small percentage for unaccounted loss is added, and the total obtained is
subtracted from 100%.
3.1.4 BOILER PARAMETERS:

Boiler contains five parameters:
1. Boiler Drum
2. Super heaters
3. Reheater
4. Economizer
5. Blow Down
In the power plant boiler parameters connecting in the furnace as shown in the
fig3.4 [8]
Fig 3.4 Boiler Parameters

BOILER DRUM:
The function of boiler drum is to separate steam and water from the steam
generated in the furnace walls and to reduce the dissolved solid contents of the steam to
below the prescribed limit of drum. The boiler drum consists of cyclonic separate steam
and water which is located on the upper front of boiler. Generally in power plant used
drum is shown in fig 3.5
Fig 3.5 Boiler Drum
SUPER HEATERS:
Super Heaters always try to maintain the constant steam temperature during
variation of coal. In practice, fluctuations occur and the necessary control to be achieved
by using a super heater spray's. Boilers have contact type super heater spray by which
feed water sprayed is controlled by automatically controlled system, which is designed to
maintain set final steam water.
REHEATERS:
The main purpose of reheat is to increase the dryness fraction of the steam. The
advantages of reheat are to reduce the specific steam consumption and consequently
reduce the size of the boiler. The efficiency of the boiler can be increased by increasing
the pressure and temperature of the steam entering the turbine. Due to expansion the
steam becomes wet and can lead to corrosion.
ECONOMIZER:
The economizer is a feed water heater, deriving the flue gases from feed water. In
turn this depends on the flue gas temperature leaving the boiler and the feed water inlet
temperature. A typical return bend type economizer is shown in the fig 3.5.
Gase."!
To
i i
-o
Boiler
Out Header
c
3
:>
c
3 LJet Header
c
w \l' \|/ i
o - < — Feed Water
Gases
Fig 3.6 Economizer
Types of Economizer:
1. Plain Tube Economizer:
The tubes are made of cast iron and their ends are pressed into top and bottom
headers. The economizer is placed in the main flue gas path between the boiler and the
chimney. The waste flue gases flow outside the tubes and heat is transferred to the water
flowing inside. High efficiency can be achieved by maintaining the water walls soot free.
2. Grilled Tube Economizer:
This is the type of economizer used in the power plant. Rectangular grills are cast
on the bare tube walls; economizer tubes may have finned tubes to increase the heat
transfer rate. Thicker fins offer greater efficiency than thinner ones because of greater
surface area.
BLOW DOWN:
In all boilers a proper chemical balance must be maintained, this manner in which
this is done can interact with feedwater control system. The chemical control involves the
chemical control involves the chemical content of the boiler feedwater-plus-the much
smaller quantity of the boiler water conditioning chemicals.
Chemical iii Feedwater
i
Boiler Steam
Cemical couceutiatioii "*• (Chaemical free)
Cheimcal blow(lo\îi
The boiler steam scrubbers are interacting to prevent any carryover of the boiler
water chemical content in the steam. All chemicals that enter the boilers through
feedwater must ultimately be removed in the boiler blow down.

3.2 HIGH PRESSURE BYPASS SYSTEM (HPBP):
The HP BYPASS system enables boiler operation and loading independent of the
turbine this allows quick rising of the steam parameters to a level acceptable to turbine
for rolling during startup. Steam bypassed from steam line to cold reheat line (CRH)
through HP BYPASS and from Reheater through hot reheat line (HRH) to condenser
through LP BYPASS [6]. The HP BYPASS valve can handle maximum of 60% of full
load turbine steam flow.
3.2.1 Arrangement of HPBP system:

Arrangement of HPBP system shown in fig 3.7 and its logic diagram in the plant
is shown in the fig 3.8 [8]
To
TURBINE
-CRH
BP
IXJZZZ—BBP
•CRH
Fig 3.7 HPBP System

The HP BYPASS consists of two parallel branches that divert steam from the main steam
line to CRH line. The steam pressure on the valve up stream side can be maintained at
desired level. The steam is Desuperheater in order to keep the steam temperature in CRH
line within limits, below 345 C and pressure of 450 Kg/cm .
The main steam pressure ahead of the turbine is maintained by the number of
pressure reducing valves BP-1. and BP-2 complete with valve mounted electro hydraulic
actuators the steam temperature down stream of the HP BYPASS station is maintained by
two number of spray water temperature control valves BPE-1 and BPE-2 complete with
valve mounted electro-hydraulic actuators. The spray water is available from the BFP
discharge line there is also one spray water pressure control valve complete with the
valve mounted electro hydraulic actuators.
The HP BYPASS function is to maintain main steam pressure at set valve whenever it is
in service. For this purpose its control system will include two number of pressure
reducing valves BP-1, BP-2 complete with valve mounted electro hydraulic actuators. In
the bypass also steam is throttled from inlet pressure to outlet pressure. This releases lot
of heat which increases the down steam temperature. Hence require to give spray water is
achieved by two number of spray water temperature control valves BPE-1 and BPE-2
complete with the valve mounted electro hydraulic actuators. The spray water is available
form BFP discharge line there is also one number of spray water isolating valve (BD)
complete with the valve mounted electro hydraulic actuator.
-;^"&
1MJ3W«i2J mMiKfkaa-.
•• -* ^ i f t W H A t A . f i r . - * •
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r •* • « «ate - I ^-w • 4« M ^
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' t ' " i " * W T l i 4 l j - * i» " • • ^ t j i i l f i »if#—••<•••» * * i i ' ' > - mmi-tf' •<•._ J Jai
• ' «•«*-*»-'• * J - . . , ... ., ^ . . . . ,_ _ ^ i n
tB '-3t.- ---^••-"
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i,«iiiKt) (/ $imtm msi icaEa3C5i»"aiii,.jff L3XE

Fig 3.8 Logic Diagram of HPBP system
3.2.2 Application of HPBP:

The purpose of the HP BYPASS station is to allow the steam pressure at the HP
turbine inlet to be controlled and during turbine startup as well as during trip and shut
down conditions by the BP valves. In addition the pump steam is attemperated via the
BPE valves to the temperature with the cold reheater inlet.

3.3 TURBINES:
Turbine is a device consisting of blades mounted on a cylindrical metal object which is

kept on a shaft itself is coupled to the generator [6]. This motion of the turbine rotor is
transmitted to generator in which mechanical energy is transmitted to electrical energy.
Overview of turbine in the large scale power plant as shown in figure 3.8 (a) [8].
Fig 3.9 (a) Turbines and Condenser overview

The steam produced into boiler expands in the turbine. In the turbine the thermal energy
of the steam is converted into the kinetic energy. Generally turbine having blades rotating
by steam is shown in fig 3.8(b) [2].
Fig 3.9(b) Turbine Blades

3.3.1 Types of Turbines:
Turbine is divided into three categories, they are:

High Pressure Turbine:
The stream from the boiler drum first is sent on to the HPT, where it rotates the
turbine. Here the steam temperature is 540 C and a pressure of 170 Kg/cm and most of
the temperature and pressure of is used by the HPT itself.
Intermediate Pressure Turbine:

The steam from the reheater is sent to the IPT, where it is used to rotate the
turbine. This is having temperature of 540°C and pressure of 4.5 kg/cm^.
Low Pressure Turbine:

The expanded steam from the IPT is sent to the LPT but the pressure decreases to
a negative value of-0.8kg/cm^.

The steam after expansion ft'om the turbine goes to the condenser. The use of turbine
increases the efficiency of the "plant by decreasing the exhaust power of the steam below
at atmosphere. Another advantage of condenser is that the condensed steam can be
recovered and that provides a source of good and pure water to the boiler and
condensable gases can be also removed from the steam by through the condenser.
3.4 GENERETOR:
Generator is a device, which converts mechanical energy of the shaft into
electrical energy by electro magnetic induction [6]. It consists of a stator and rotor and an
excitation system. This electrical power transmitted various load enters through the
transmission lines.
NTPC-Ramagundam generators 2600MW power of which 3x200MW in Stage-1,
3x500MW in Stage-2 and IxSOOMW in stage-3 capacity. Low pressure turbine to
generator overview is shown in fig3.10 [8]
Fig 3.10 Overview of LP turbine and Generator

3.4.1 OPERATION OF GENERATOR:
An electrical generator is a machine that converts mechanical energy into
electrical energy. The energy conversion is based on the principle of the production
dynamically induced EMF. Whenever conductor cuts flux dynamically induced EMF is
produced in it according to faraday's law of electro magnetic induction. This EMF causes
a current to flow if the conductor circuit is closed. Hence, basic essential parts of an
electrical generator are a magnetic field and conductors, which can so more as to cut the
flux.
The basic law or principle of operation of all rotating machine remains the same
that is faraday's law of electro magnetic induction. It states that whenever there is
relation motion between a conductor and a magnet that is when a moving coil cuts the
magnetic lines then an emf is directly proportional to the rate of change of flux and the
number of turns thus to produce relative motion either the armature rotate on the magnet.
e = N <1^
(It
Thus to produce relative motion either the armature to rotate on the magnet. In a
DC generator, the armature is rotating part and in alternator, it is a stationary part. The
rotation part (rotor) produces the magnetic field and armature winding is the stator.
Specification of 500MW Generator:
Make BHEL
Type THDFl 15159
Code IEC34-l,VDE-0330
Apparent power 588MW
Active power 500MW
Power factor 0.85 (lag)
Terminal voltage 21KV
Permissible variation in voltage ±5%
Speed / frequency 3000rpm/50Hz
Hydrogen pressure 4Kg/cm^

Short circuit ratio 0.58
Field current 4040amp
Field voltage 340V
Class Class F
Type of insulation MICALASTIC
No of terminals brought out 6
STATOR:
Volts 21KV
Connection DELTA-DELTA
Amps 16200amps
Coolant Water & hydrogen
Winding U-STAR 0.001524
V-DELTA 0.001522
ROTOR:
Volts :340V
Amps : 4040 amp
Coolant : Water & hydrogen

3.4.2 CONDENSER:
The use of a condenser in a power plant is to improve the efficiency of the power plant by
decreasing the exhaust pressure of the steam below atmosphere [6]. Another advantage of
the condenser is that the steam condensed may be recovered to provide a source of pure
feed water to the boiler and reduce the water softening capacity to a considerable extent.
A condenser is one of the essential components of a power plant.
Types of Steam Condensers:
Mixing or Jet Type Condenser: These types of condensers are mainly of two types.
Parallel flow type and Counter flow type. The parallel flow type the steam and the water
flow in the same direction and in the counter flow type they flow in opposite directions.
These types are rarely used in high capacity modem day power plants.
Non Mixing Type or Surface Condensers: In this type the cooling water and steam do
not come in contact with each other. This is used where large quantity of inferior quality
water is available. In this the cooling water flows in pipes and the steam flows iii a
perpendicular direction to the pipes. The velocity of water flowing is very high to absorb
the heat from the steam. This condenser can be classified based on the number of passes
of the tube and the direction of the condensate flow and tube arrangement, either down
flow or central flow.
Condenser system and Deaerator tank with Condenser Extraction pumps shown
diagram in fig 3.11 [8]

CONDENSER SYSTEM:
itAMASUNDAM
Fig 3.11 Condensate System

3.4.3 CONDENSER EXTRACTION PUMP (CEP):
Steam is condensed in condenser so tiiat becomes water this water is stored in hot
well. CEPs are used to pump, this water from hot well to Deaerator [2]. Condensate
extraction pump (CEP) is a part of condensate system, which is to send condenser from
hot well to deaerator through ejectors, gland steam coolers and three LP Heaters. Three
pumps are installed below zero meters. Water with deminaralized and low temperature
steam from low pressure turbine (LPT) passes to the condenser through different valves
to tubesheet it is mixed water and steam finally water goes to hot well tank in which store
the water. General simple diagram of CEP is shown in fig 3.12
To ejector
Water outlet Steam vacuum system
Af •
•I
EC^.
•=
£ m
Tubesheet I Tubesheet
Condensate
Water inlet
Fig 3.12 Condenser Extraction Pump
Each pump is capable of 50% that is two pumps will always in service and other pump
will be in auto stand by. CEP is driven by 6.6KV electric motor. Pump is directly coupled
to motor by rigid coupling. CEP is a multistage vertical centrifugal pump comprising of 4
stages. It has a bearing with radial and thrust type which is cooled by cooling coil
circulated by cooling water. The circulation of the water form condenser to Deaerator
through condenser extraction pumps as shown in fig 3.11 (Condensate System).

CEP suction line is taken from hot well individually each suction line has 1 manual
suction valve followed by a suction strainer on discharge side, their discharge valve from
a common heater discharge and further flow through ejectors, LPH 1,2,3 and finally to
Deaerator.
Specifications [7]:
Supplier Worthinston
Type 12QLQ021/85/4
No of stages 4
Inlet temperature 49.2°C
Discharge pressure 30.45 atm
Pump speed 1485rpm
Capacity 860.3 m%r
Total dynamic head 370m
Speed 1450rpm
Each CEP which is driven by an 1120KW induction motor, delivers 810000kg/hr at

condensate water against 370m of total dynamic at rate condition.

3.5 PRESSURE HEATERS
In the Ramagundam Super Thermal Power Station (RSTPS) have two types of pressure
heaters they are:
1. Low Pressure Heaters (LPHs)
2. High Pressure Heaters (HPHs)
3.5.1 LOW PRESSURE HEATER:

It is a three stage heater where the temperature of the water is raised to 130*^0.
The pressurized water from the condenser extraction pump (CEP) passes through the
coils present in the LPH. The steam tapped from the low pressure turbine (LPT), is used
to heat water.
3.5.2 HIGH PRESSURE HEATER:

It is a three stage pressure heater, in which the tapped steam from turbine is used
to heat the feed water in HPH. The discharge from each pump comes to a common
header before entering the high pressure (HP) heater no: 5A, 5B, from this feed water
flows 6A, 6B and then to economizer. HPH 5A, 6A can isolated separately and HPH 5B,
6B can be isolated separately.
The feed water heaters are surface heat exchangers which extract heat from the
turbine extraction steam and heat the feed water.
3.5.3 Extraction Steam System for Heaters:

The steam pressure and temperature is low from Low Pressure Turbine (LPT) is
not directly goes to condenser, its goes to LP Heaters 1,2 and 3 which LPHs steam is
converted into water then this water passes to condenser. Steam goes to condenser for
increasing water temperature in condenser coming from cooling towers.
The high steam temperature and pressure from High Pressure turbine (HPT)
passes to Reheat, some steam not goto Reheat its goto High Pressure heaters (HPHs) and
also Intermediate Pressure Turbine (IPT) passes HPHs, which HPHs converted, steam to
water, this water passes to the condenser. Feed water passes to boiler drum through HPHs

where water temperature increases at low pressure to economizer inlet. The discharge
from each pump comes to a common header before entering the high pressure (HP)
heater no: 5A, 5B, from this feed water flows 6A, 6B and then to economizer. HPH 5A,
6A can isolated separately and HPH 5B, 6B can be isolated separately. Steam extraction
to heaters is shown in fig3.13 [8].
mTm&
ct J
m
Fig 3.13 Extraction Steam System for Heaters

3.5.4 HP Heaters:
There are two HP heaters in the feed water system. They consist of shells which
are made of tube sheets. U-shaped tubes are mounted horizontally inside the shell. In the
power plant used High Pressure Heaters as shown in fig 3.14 [8].
MSSSSSc-
"fi-
' =44 ilL./>l>i^',jf^
wsfm -BSS •if^ wrr Esrm,:

\r -• 1-. • • . " * ( « »:«£-mSlB.C_v«- . ^^^ fl<'.-'tn.«.»j;. IT , . i . .„>
••- • •>!•>•«•• ir-r-i-jrai .•«•••

fP?!'
^^cn^-: TM 7.1:,'.
'iH —>.niri.j -- gr~--'rT:.i'-
^mg^^îmi^^cik
' • • • . " ? ^ '•'*V'^?^^?***.'j!|**'rrf*''w''f''~'-*'.'T'!gfr'W>\'JiF.''»'.?<>Tfr'rti--Â-!fe»iii^ '«—• •• .-• • .
Fig 3.14 High Pressure Heaters
The HP feed water heater can be divided in three zones.
1. Condensing zone
2. Desuperheating zone
3. Sub cooling zone

> In the condensing zone a large volumes of extraction steam condense
and maximum heat transfer takes place in this zone.
> In the desuperheating zone of HP heater, the superheating available in

the extraction steam is removed. As the velocity of extraction steam is
high, condensing is not desirable in this zone.
> In sub cooling zone drip is cooled.
3.5.5 Specification of HP heaters:
Contents HP 5A/5B HP 6A/6B
Shell side 24 full vaccum 574 full vaccum

Tube side 330 atg 330 atg
Tube surface area 964 m^ 964 m^
No of water passes 2 2
Tube outside dia x thick 5/8'' x 12 & 13 BWG x 8650 5/8" X 12 &13BWGX 10200
Material for tubes S.S.SA688TP304 S.S.SA688TP304
No of tubes 1181'U-tube' 1181'U-tube'
Water velocity through tubes 2 m/s 2 m/s

3.6 DEAERATOR:
A steam generating boiler requires that the boiler feed water should be avoid of air and
other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the
metal. Generally, power stations use a deaerator to provide for the removal of air and
other dissolved gases from the boiler feedwater [6]. A deaerator typically includes a
vertical, domed deaerator section mounted on top of a horizontal cylindrical vessel which
serves as the deaerated boiler feedwater storage tank. There are many different designs
for a deaerator and the designs will vary from one manufacturer to another. The adjacent
diagram depicts a typical conventional trayed deaerator.If operated properly; most
deaerator manufacturers will guarantee that oxygen in the deaerated water will not exceed
7 ppb by weight (0.005 cmVL). The Deaerator diagram shown in fig 3.15
•^ Air vent
^ Boiler feed water
Trayed r
section \
Deaeration steam
boiler feedwater
Pump
-' •- Internal steam distributor piping
T Internal perforated pipe (water distributor)
- Perforated trays
— L o w pressure steam
- Boiler feedwater
Fig 3.15 Deaerator connected with BFPs
Deaerator connected hotwell tank, which store the water. Feed water passes to drum from
hotwell tank through Boiler Feed pumps (BFPs).

3.7 FEED PUMP SYSTEM
3.7,1 FUNCTION:
The function of the Feedwater System is to supply high-pressure water to the
boiler during startup, normal, and emergency operations. The System automatically
maintains the proper flow to water level in the boiler drum. The Feedwater System also
supplies water for Desuperheater Sprays that control the Superheat steam temperature.
Boiler Circulation Pumps:
&ima:'.&m
SPEED; 0 . 0 0 0 0 fiPM
BLR CIRC PUMPs
LOAD : O.COOO MW
vtm VFwr
am mm IEWSIUEGC)
[""' rziZjijrJizo ' SB K Btlt J3I

CWtEMP.I 3fl' 3n an-
e w IMP-2 W\ 3li Mli
CSttftp ""] 30i " 3 0 301
eaw.B BOTjp-c
FWFl 0.0
[iRPP 0.0
i..v<«ii £CVW)BSTRP^*
AfKAll AtitTep
fW
TOWATERW/tLL
litXi SEC/C-; PfJ/JK
ffi.WF* Vrmhm P.«'H>.5S *
f.'.«r Viin.m laiTrA
Fig 3.16 Boiler Circulation Pumps
The fig3.16 [8] shows circulation pumps between boiler and deaerator through
boiler feed pumps.

In NTPC-Ramagundam, 500 MW unit 3-BFPs are used, 2-BFPs are driven by a steam
and it's known as "TURBINE DRIVEN BOILER FEED PUMP (TDBFP)" consists of
2TDBFPS A and B. I-BFP is driven with electric motor known as "MOTOR DRIVEN
BOILER FEED PUMP (MDBFP)" which is always in standby position. If in case, any
problem exists with TDBFP then a used to MDBFP.
3.7.2 BOILER FEED PUMPS (BFPs):
Boiler feed pump is part of feed water system which is used to feed the water to
boiler at high pressure, there pumps are located at zero meter level of turbine hall. Each
pump is capable of carrying 50% load, i.e. two pumps will be always in service that
TDBFP and one pump is auto stand that MDBFP by at full load condition. BFPs are
driven by 6.6KV electric motor through hydraulic coupling. Generally in 500MW unit
two types BFPs are used, they are:
1. Turbine Driven Boiler Feed Pump (TDBFP)

2. Motor Driven Boiler Feed Pump (MDBFP)
TDBFPs are driven with steam, where as TDBFP is driven with electric power,
TDBFPs are more efficient than MDBFP because power consumption more in the
MDBFP. Feed water flows from Deaerator to drum through pumps efficiently level of the
drum depend on the speed of the BFPs. Overview of the feed water system and water
supplied to Boiler drum Feed Water system is shown in the fig 3.17.

EAMAGUNDAM
Sir-MH
je>ir/:v«<:iA» -T i X -
-O-^F ^
W^; x: f ee
w«—
is
i>
itrnai (o-.-iM
•sa—fe(<i—»
c
t:-(vai s-Atli
sH! -0K3 HN-
- £ ^
^l
_..._^ |p>-..
#*-
'tr-A(U *il'AlU
' •• i S £»
I
':'G^- . . . ^ - ^ ^
•j?.-An.4
I[
l.J
-r
l-CAUi
m-*~>-
îi
W*—
»-
Si
•i-fMi a-f.ai
VSS P>r* *
BC'ACU U-MU
ti
ii?"
Fig 3.17 Boiler Feed pumps

3.7.3 TURBINE DRIVEN BOILER FEED PUMP:
The steam turbine driven is tlie main power drive variable speed, motor driven
startup and steam by feed pump provided. Using a steam turbine as the main power drive
on increasing in overall unit cycle efficiently because the steam bled from main turbine.
The steam utilized in the feed pump turbine can be further used in the feed heating
system.
3.7.4 MOTOR DRIVEN BOILER FEED PUMP:

The electrically driven startup/standby boiler feed pumps are controlled by same
derived signals, there speed is adjusted by altering the electrical resistance of the rotor of
the motor pump or through variable speed coupling fitted between the pump and motor.
3.7.5 DESCRIPTION OF TDBFP
Optimal performance of boiler feed water pumps is very important not only for the pump
designers and manufacturers but also for the operators of pumps in power plants. Boiler
feed water pump is a specific type of pump used to pump water into a steam boiler. For
any boiler operation, boiler feed pump is an important part as they can control the amount
of water fed to the boiler and the manner in which it is fed.
The main feed pump is expected to have the following performance data:
> Flow rate - 700 kg/s

> Pressure increase p - 300 bar
> Temperature t - 200 °C
> Speed n - 4620 rpm
> Power P-67 MW
> Efficiency - 87%

Main pump and booster are both driven by a steam turbine; the speed of the main pump is
continuously variable, the pump set reaches a maximum speed of n = 5670 rpm. It
delivers hot water at a rate of 895 kg/s and has a power input of just under 42 MW
(around 2 MW of which are required for the booster). With performance data like these,
the pump is at the top end of the range of machines referred as large feed pumps.
Structure of TDBFP is shown in fig3.18
The TDBFP unit consists of three components:
> BOOSTER PUMP

> DRIVE TURBINE
> MAIN PUMP
DE.4EEAT0R
BOttER
>\
TURBINE
\/
BOOSTER REDUCTION HYDRU.ÎC MAIN
PUMP
q PUMP GEAR COUPLING
/\
Fig 3.18 Structure of TDBFP

BOOSTER PUMP:
The booster pump is a single stage pump, which increases the suction pressure of
9Kg/cm^ to a discharge pressure of 25Kg/cm^ speed of booster pump is MOOrpm.This
increased pressure feed water at a pressure of 24Kg/cm flows to the suction side of the
main pump from the outlet of the booster pump.
DRIVE TURBINE PUMP:

A driven turbine drives this pump; hence the name of "Turbine Driven Boiler
Feed Pump" and the drive turbine are located in between the booster pump and the main
pump.
MAIN PUMP:
The main pump is of multistage centrifugal type 4+1 kicker stage. The pressure of
feed water in increased from 24Kg/cm^to nearly 216Kg/cm^ in the 4 stages and the in the
1^' stage i.e. in the kicker stage the high pressure feed water is pumped to the boiler,
where the gets the evaporated for steam formation, the speed of main pump is SOOOrpm.
In the power plant control of TDBFP as shown in fig 3.19
E8iS8p'*->u-—''*'SBirJOL- • - ' ' • ' « i : . " . « i ' l l M ' . -»«(iii/."f « * - ' • ,F i. , . , • - " - ' l,i "••fcl
-SKIS - B 3 ' . ' r*f'-^t - - '•WLi,..^
f7?TTT
^S
—1 r
?*X:
L . , - - >«^Mhp^ I • -Al '•••M** •••••'• "I
r •' -'• • •• -J It. • 1. • ' T ' -"*• I J
- *«» - # - ifc— ' * * ^ I
'i \"'.n
-I"
» fi Ji .- -.•• •tar-
: ^ M r ' i l * S » s t aiCow/ M!5£tt-;
' mmMA Kii*.?*i
Fig 3.19 TDBFP-B Control
MOTOR DRIVE BOILER FEED PUMP:
In the MDBFP The water from the deaerator to boiler with MDBFP through
booster pump and main pump in between motor running. Motor require external power
supply 6.6KV.

The general structure of MDBPF is shown in fig 3.20
DEAREATOR
BOILER
/\
v/ MOTOR
BOOSTER HYDRUALIC MAIN
pimip COUPLING PUlvIP
/s
Fig 3.20 Structure of MDBFP
3.7.6 PHYLOSOPY OF TDBFP:
In earlier days, during 200MW generating units BFPs were driven by motors but
due to advancement in research and development the 500MW are driven by turbines of
single cylinder.
A turbine driven boiler feed pump consume 2% of out power that is generated,
where as motor driven pumps consumes nearly 5% of out power generated for running its
auxiliaries. Therefore by using a TDBFP about 3% power generated can be saved which
may be supplied out side and gain more profits.
SOURCES OF STEAM FOR DRIVING TURBINE BFP:
There are three sources of steam of steam by which turbine of a boiler feed pumps
can be operated. Auxiliary steam from the auxiliary pressure reducing and desuperheating
(PRDS) station. PRDS station gets steam from either of the sources.
Main Steam (MS)
Cold Reheat Steam (CRH)
Auxiliary Boiler

In the PRDS station pressure is reduced to 16Kg/cm^ and steam is Desuperheater to 320*^0
(for HT PRDS). This source of steam is supplied at a rate not more than 10 tones/hr.
steam taken from cold reheat (CRH) line or 6* extraction (HPT exhaust).
3.7.7 ADVANTAGES OF USING TDBFP OVER MDBFP:
> The use of an independent steam turbine increases plant capability by eliminating
the auxiliary power required for the boiler feeding.
> Proper utilization of the exhaust steam in the feed water heaters can improve the
cycle efficiency.
> In many cases the elimination of BFP motors may permit a reduction in the
station auxiliary voltage.
> Driven speed can be matched ideally to the pump optimum speed.
> A steam turbine provides variable speed operation without an additional
component such as hydraulic coupling.
3.7.8 SPECIFICATIONS OF TDBFP & MDBFP:
Contents TDBFP MDBFP
Manufacturer BHEL BHEL

Pump FK4E6 FK4E36
Rotation Anticlock Anticlock
Suction pressure 23.4atm 24.44atm
Discharge pressure 216.76atm 216atm
Speed 5670rpm 5670rpm
Power required 67552KW 6752KW
Efficiency 81.75 8.75

¥
Jl MiB4
PIl) COIVTKOLLER
&
MaxDNA

4.1 PID CONTROLLER
PID-ControUer Tuning Optimization for Power Station Processes:

A proportional-integral-derivative controller (PID controller) is a generic control
loop feedback mechanism (controller) widely used in industrial control systems [10]. A
PID controller attempts to correct the error between a measured process variable and a
desired set point by calculating and then outputting a corrective action that can adjust the
process accordingly and rapidly, to keep the error minimal.
The proportional, integral, and derivative terms are summed to calculate the
output of the PID controller. Defining u{t) as the controller output, the final form of the
PID algorithm [10] is:
u(t) = MV(t) = Kj,e{t) + KJ e(T) dr + xAt)

e{t) = Enor
Kp = Piopoilioualgaiii
K,i = Diffeaentialgaiii
Ki = Literal saiii
4.1.1 Basic Interactive PID Controller Function:
Oiirput = Fie+Ije.(it + D—\
Where P = gain, t = Integra! or Reset and D = Derivative or Rate
Fig 4.1 PID Controller action

Basics of PID:
> Most industrial controllers are used PID controllers:
• P- Proportional
• I- Integral
• D- Derivative
> PID Controller:
• P Applies GAIN to the error signal

• I Applies integration (or RESET) to the error signal
• D Applies differentiation (or RATE) to the error signal
> PID Controller:
• P, I, D Parameters are set according to system characteristics and the

response characteristics desired
• Works to reduce the error signal to zero
4.1.2 Controlling Process:
The new approach for PI/PID controller tuning of power station control loops.
This tuning is fulfilled in the frame of the robust theory approach by using four object-
oriented criteria for power station processes. High accurate identification of process and
its uncertainties provide the robustness basis of the controller optimization. Based on this
approach the Control System Tuning Package (CSTP) was developed and successfully
applied for control loops tuning of power units.
In thermal power plant control loops controlling parameters are temperature,

pressure, level, flow, load and other parameters of power station units. Optimal control
loop tuning of such loops is a way for increasing efficiency, robustness and survivability
of the power unit. This tuning is obtained by adjusting of PI- or PID controller
parameters.
The boiler system and its PID control system, for detecting operational errors when boiler
and control system interact, and for developing and implementing a protective wrapper
dealing with such errors. Boiler System and Control System (including the PID
Controller) is shown in fig 4.2.
Dnaa Lcvri Stam Flovf. Steam, OiS<i-p<M<ii*a4t>tK
Co3l Fe«d« Rale
Coalittl Systeiu /
\ • ' /
COllfllLM^liotl
Co<il Qtsalitv
Swisois InpimtoPID", PID controUei'
Boiler
ChiiinttiftomPID
System ActitatDfi
Steam Load
X /
-•
Fetd WatH Floif. Coed Fwder

Rat* Mid Ail'Flo*
Fig 4.2 Boiler System connected sensors with PID Controller
Simulink Model of the Boiler System with PID Controllers:
Three separate PID controllers that deal with the feed water flow, the coal feeder
rate and the air flow [14]. These controllers output three eponymous variables: Feed
Water Flow (F_wf), Coal Feeder Rate (Cfr) and Air Flow (Airf); these three variables,
together with two external variables (Coal Quality and Steam Load) constitute the
parameters which determine the behaviour of the boiler system. There are also several
internal variables generated by the smart sensors; some of these, together with the
configuration set points, provide the inputs to the PID controllers.

PID Cofltroller 1forFeed
Water Flow
HDCoiarollerlfor
Coal Feeder ipm
PID CoctooUet 3
for Air Flow
Boiler System
Four parameters of PID-controiler, G, R, D, To, are optimized simultaneously

according to its transfer function.
C(,) = G + ^ + ^'
Rs T^-s + l
C(s) = Out put response

G = Gain
R = Response time
S = Complex conjugate
D = Differentiating gain
TD = Time constant
AO = Phase margin
sdmax = Standard deviation
vSmax= Control valve maximum speed

4.1.3 DETAILS OF DRUM LEVEL CONTROL CORRESPONDING TO PID
CONTROLLER ACTION:
The fig 4.3 [8]shown in the above diagrams are of different parameters set values
of different parameters give as a input of PID Controller, these different parameters in the
power plant viz, Level Set point, set point of actual level, main steam flow, and steam
temperature corresponding values given respectively.
Msnber IVilue • '•" 1Reference (Catifory jCescrlption Security Class^

Out t « . 91674 Status Siisipk output 5(Cartfisur«io~
OUTCTL B.ea818«?821 ./sr.OarCti : Output Control I r i p M t f l t Output 6(ModeCh«n|e)
OutPct « 54,9W74 Statui Ôutput .osrceitt teed on r ^ p -
S(Cofifigurstio
Perturb- i 6.6 TunwgTejt iValus o f step change f o r tufiing 4(Tune/Adjust)
frepSPMuk J «.e Conftg Properrional set pnt ftuHiplisr 4(Tune/Ad3ust)
W > $.mm% : Status Prsvlous JCSitis' PV value 5(Conf1guratla
PVBad I.S ,/»iS?,out i Output 8(MBt!eCh«nie)
PVInCtl a.S973B55 FiillOADJTOOfi. OytC. Input ^ Control 1 er Process VarTabl e 8(Mo(teChanse)
PVQuality 8.8 ,/?i8?.In0ual : Output PVûsllty a^ModeChsnge)
Race s.e •Tunliig PIP Rate ISst §(ModeChsnge)
feteSPMuIt > 6,8 'Xmfi% :B«e set point m l t i p l l e r 4(Tune/Ad3«si)
Mtt J,529412 TuniRg .PIO Reset OOôdeChange)
ShOesc J"8FP CTLMstr" ,Psrai!tt£er Short dtstrtptiftn 5(Coftfl3uratio
Sf « e.8 ^Status Setpsint 5(Conf1gur*tlo
iSP«%hteg 123,6 .m.S9Mtmi •Output eôdeChange)
•SPLwRng -188.8 .its.%?uii\m Output 8(HodeChafi§e)
SPModeLocal 9.a Input Set Local Setpoint Mode SOÎodeChange)
SPHodeReniote i.e Input Set Ramte Setpoint Mode BjJfodeChange)
SPOpDcuSielscrm > 5,0 ' ConfigLlfflis; Input D J(Confl9Ufatto
SPOpSliiglelncnn i l.@ ;CoRfl3Llnti,MnpytX 5(Corifisurat1o
SfRat^Lntt i M.e CorsflgLimft;Output incr ntt of change limit 5(Config«r&t1o
snemmtcim t 8.9 Tuniri|teat SP Windup deviation tolerance JIJune/Adjust)
SPiêiwkWHys ) iA _.Tu.n1ngReniotHi^StB;esls for SP aritiwindtf 4(Tune/Adjust)
SPBeraAftllndtt 1 8.8 iTuninpRemotiSF Windup deviation tolerSce , 4(Tune/AdJust)
SFRewteActv • True 1 Status Operatlrts in suto when true I(Configuratlo
SPReratelnCtl t.8 :ATAG_Z£RO_SP.Out£t Input fien«t€ S e t p i a t Input ,8(HodeChartge) ,
SPRemoteSelsm »Tnji» Status e s Manuil, 1 " Auto 5(Confijuratio-J
S?i?aret8Susp e,e Input %ifs«<nt Rewte Op Suspena' ,e(ModeChange)
SPTrftTrack J no cracking changesi Ofily by •Conflg Tsrpt cracking option 5(ConfIgurstto
ftgfjw; •SLAElSDFlSr' JParaiEter TagN^ J(Confi|urat1o»|
HJ
Fig 4.3 (a) Drum Level Control parameters corresponding PID Control action

Mwier TvaiuT iRafereftce .K»te9ery jSesgriptlon
Out
J4.Si6?4 Status
OUTCTL SisifjU aiitpgt
S8818S?821 ./*5.«urCd Output ^CConfiguratfo"
OlitPCt Control tncremK Output
I4,51Sf4 .8(HodeCh8iig«)
PertMrb iStMus /.Output percent based on range
8, a 5(Cotif!gurai:1o
PropSWul t iTuftinfTsst Value of sc«p chanae for tuning
^4(Tune/fe(iust)
PV Proportional set pnt fsultipller
.40«ne/Ad3ust)
'PV8ad J Status Previous scans' PV valuf
8.8 .A28?.0uc S^CConfiguratlo
PyinCtl
Output
FULLwAD.tRROS.fofC'lnput S^HgdeChange)
WSuality Centro! 1 ar Pracess V ^ l a b l e
./PM.imm) jftucput ^(ModeChangs)
SKe PV ûal ity
;8CHodeCfsa,ige)
iTuninjf PID'Sate tiffle
RateSPMult ;5(ModeChang«)
•Config
Restt Sate i « point multiplier • 4<Tur!e/Adjust)
3.5294iJ
ShBesc "BFP CTL Hstr" PID Reset • ' ' ^l , . sliodeCharsge)
$f ?»r!m5t6r ^ Short descrljtl on
H'Canfiguratio
SPHigkng iSetgaint __
./#5.SPInaiRHI 'Outfiut •5(Configuratio
SFLowSng 8(HBdeChange)
-188.e ./*S.SPIn<tiRLO Output
SWodcLoca) 8.8 I^ModeChange)
Jnpiit Set Local Setpoint Mode
_SPMoci6Re))',ot:e 1.8 8(HodeCh«nge)
input Set Remote Setpoinc Mode
sSideChanse)
Corif1|Liftt> Input 0
[SPOpSlngleincrm .JCConfisuratio
ConflgUfliit: ingut C _^
SPS&tsLnit leiTs S(Con_f1|urstlo
ConfigLltcn Outputlncrj-ate of change f i m i t
SPRe««*lDeclfflt >(^*|ipr«'o
Tuniiif|einot ;SP W.^dup de'/iation tolerance^ 4(tun«/Adjust)
SPteMWHys
e.e Kystefesis f w SP a.itiwin(!'«p <5une/Adjwt)
y : _ .TtinlrtgRTOti il ÎsiyP o'ei'iat 1OT, to! erance •ftiw/Adjast)
SPteMOceActv »True
•Sistu? •apirsting in auto nten true 5(Conflguratio
SPRsRotsInCtl
6.8 • ATAC_2£W_5P. OutCt I n j u t ' " " RMot_s Sstpoiftt Input 8(ModtChMge) .
SfRffloteS«1«ttd >Tru«
Swtw i » Manual, i « Auto _ S(Conf'i5uratioJ j
SPfiesoteSasp
SPTrgcTrsck Setjoint fimote Op Suspend SiJModeChanie)
>m traeklnj changed only by Confip
i j a r i s t trackjR§ option SCiCorsfiguratlo
5(Caftf1gur«t1o»|
"'" " ^f
Fig 4.3 (b) Drum Level Control parameters corresponding PID Control action
Drum level control with PID Controller:

According to PID-level controller. The initial Pl-controller has parameters of
G=4, R=300. Pl-optimal parameters calculated by the CSTP are G=6.2, R=450.
Requirements for optimal loop operation are as follows:
a) Minimum response overshoot to the set point step
b) AO = 60deg, sdmax = 0.1 %, vsmax = 10%/s

The corresponding responses are shown in Fig 4.4.
Timeres-ponse of cinmile\el conhol
I
1
1
1
1
L
1 1 1 1 1
1 , 1 1 •
A •! ft 1 KIM. ' •
J* ' p
1w 1 r •
f"l 1 1 1
^ / 1 1 t 1
\ 1 f si 1 V^X 1 1 1 1
—
j \ Uutuued control system
1 l.f\ 1 M \ 1 1 1 1
\ Tuned control fcys-tem j

S2— 1 1 1 1
J t ' \ 1 1 1 1
— 1 y /r 1
1 / /1
1 / .^^ 1
1
1 \ Le\'el set point j j
1 r /^ 1 1
Mr ^^tf 1 1 1 1
1 ) 1 1
1 1 1 1 1 1 1
• ! > t i l l
9D ISO son 2sa soo 350 iOD 4Sa

••a Time, sec
Fig 4.4 Time Response of drum level control
Main steam temperature control system:

The initial Pl-controller has parameters of G=0.9, R= 100, D = 43, TD= 17.
Optimal loop operation is as follows:
a) Maximum integral index quality of control loop step response
b) AO - 50deg, sdmax = 0.1%, vsmax= 10%/s
The Main steam temperature control loop responses are shown in Figure. Because of
relatively low level of noise and sufficiently high value o^ sdmax , PID-controller provides
the highest quality. The Corresponding response shown in fig4.5
Mniu £:te.iiu tempeiiituie coubol system
540
Fig 4.5 Time Response of Steam Temperature control

4.2 MaxDNA
METSO AUTOMATION MAX CONTROL (MAMC) system is offering the

MAXDNA distributed control system (DCS).This product is the latest in a long evolution
operating system mission critical systems provided to the power industry worldwide [9].
This system includes a modem NT native. Human machine
interface(maxView,maxTools)', a reliable high performance fully redundant
network(maxNet),a high performance Ethernet resident DPU's and a field proven, fully
tested I/O System which provides solid, reliable service to his facilities around the world.
The model DPU which runs under Windows real-time, multi tasking OS is the
hardware processing engine of the MAXDNA DCS. The DPU performs primary data
acquisition, control and data processing functions. DPU also known as MAXDPU4E is a
self contained micro processor based rack mounted unit which occupies either a single
scot in a remote- mounted unit carbine using a 4-wide back plane.
4.2.1 MaxDNA System Architecture:
Meiwotti I
lilwSTATlOtl
itmSTOniAN
iocÎit)
Swtaiiinia Ueai®
R«iiKit«liO
Fig 4.6 MaxDNA architecture

MaxDNA system is used for in the large scale power plant for controlling the boiler
parameters it consists of MaxSTATlONs, maxSTORIAN, Ethernet Network and remote
I/O which connected with maxNET.
As a station on MAXNET, the DPU scans and processes information for use by
other devices in the MAXDNA system. Each DPU perform:
> Comprehensive alarming and calculations.
> Logging of sequence of events (SOE) data at 1 millisecond resolution
> Acquisition of trend information
> Continuous scanning ofmodelI/0 processor and I/O modules
> Execution of predefined algorithms called functional blocks for process
control and data acquisition.
4.2.2 MaxDNA System with THERMAL STATION:
Perfomiance
Advice
Parameter Bias
' Operator Override
Bias Process i
& Coefficents Variables/
/
DCS
Combustion Controls
Data Acquisition
Infwmation Management
Fig 4.7 MaxDNA System with Power Station

Operator or an engineers used for creating and maintaining conglutinations and process
control documentation using maxT00LS4E and maxVUE graphical configuration
software or it is also used to create and maintain custom graphic displays using MaxDNA
graphics software. In the above fig 4.7 [9]used ftill duplex communication between
station and plant.
4.2.3 MaxSTATION:
The maxSTATION is the hardware platform through view and manage process
control environment.
>• True open system architecture

> Noiseless communication between plant and network
> Measured and control from small process applications to complete plant
control
> Online graphic monitoring
> Online self documentation configuration
> Ultra high speed graphic building and displays updates
> Centralized engineering capability
4.2.4 MaxSTORIAN:
MaxSTORIAN is the serverless systems consist of 40GB memory hard disk
which displays controlling parameters levels and stores the data from Distributed
Processing Unit (DPU).
> Historical data collection and archiving software for maxSTATION

> Data storage maximizes system data capacity
> Relational database to simplify reports and queries for data analysis
> Archival storage to CD-ROM
> Supports interface to plant networks
> Windows 2000 based

4.2.5 MaxLINK:
MaxLINK is connected between the maxSTATION and plant sub systems
through maxNET.
> Interface to external systems: PLC networks (Coal handling plant, ash
handling plant etc.)
> Supports multiple simultaneous communication protocols
> Supports data transfer from other systems and networks
> All data available to maxSTATlONS
> Windows 2000 based
4.2.6 MaxDNA DPU4E:

MaxDNA is a Distributed Control System (DCS). The DPU performs data
acquisition, control and data processing functions.
DPU Features:
- Real-Time multitasking
- Object Oriented database
- One-to-one redundancy capability
- Diagnostics that are accessible by Workstation and PC direct connection
- 8,000 alarm/event queue to insure no-loss of alarms and events
- Flash memory for non-volatile configuration storage and on-line and off-
line firmware updates
MaxDNA DPU4E FUNCTIONALITY:

• The DPU4E is the process controller.
• The DPU4E is a multifunction processor that executes
> control algorithms,
> sequence logic,
> SOE time tagged to 1 ms resolution
> Data acquisition.

A DPU consist of a printed circuit board containing the control processor and
Input/Output processor (lOP) attached to a DPU chassis. The DPU's front panel contains
status LEDs, and takeover and reset buttons, while the DPU's front chassis panel contains
network, backup and serial port connectors, mode and network address switches, and the
key switch.
Fig 4.8 MaxDNA DPU Front Panel
4.2.7 MaxDNA THE REMOTE PROCESSING UNIT (RPU):

The Remote Processing Unit (RPU) is the group of equipment that provides
^ The control
^ Data acquisition
& And I/O processing functions for the DCS
The equipment includes

& DPUs
€i Field I/O modules
® Field terminations
© Communication networks
& And peripheral equipment such as power supplies, & cabinets.

fflffWi
RESULTS
&
CONCLUSION

RESULTS:
When the Plant is Running & REMOTE
S0DF901 XJ02.Out,^|Steam Flow 1608.315aTA^R
1700.00
1580.00
1460.00
Oesc
MarituL>e
1340.00
1220.00
17:4?: 69 11 MM 1100.00
22Jjn2e89 22:ur2M:) 22jjri20e9
mw.nm
22Jur2«)?l 1?
TDhli'-BSdcflow
IStaain Flow Moni r sut Ho\« 0.000
rse.i w.iti-i rill fTDRPPASiieeil 5428.9595.'
J 191.7861 TOerP B Sueail I 5415^23
• FWMuwnr I 51813?
Observed Data from above Result waveform:
• Drum actual level - 48.2906 MMWC

• Steam flow 1608.3158 TPH
• Feed water flow - 1618.6283 TPH
Output load 518.1385 MW
Main steam Temp - 550 C
Boiler Drum Level Control in Thermal Power Plant 7€

• When the Plant Running in normal position
)LAB11DF901_XJ01.outSffDBFP-A Sue Flow 904.9919 T/HR
17:42:66 17:56:66
221U-i2669 22X-2im 22:L"I266'1
jfumlpwel SP 60 0000- DBFPA Sue Flaw 904,9919r-i-

i rnrirr R S U I FIHW 903,40901 I'-
siciiii riow 1609.0771^" ImriRrp Sucrinw I O.OOOOt^ Hi
lleKil W^lei H<iv/ 1624 646&I I 5436.476l| f '
I 5420.9819| r
r w Fkiv^Di'rii, i>3.9488 I 513.56f.2|- • '

• Steam flow - 1609.0711 TPH
• Output load - 518.5652 MW
• Main steam Temp - 549 "C

When the Plant is Running & AUTO

• Steam flow - 1591.7889 TPH
• Output load -504.7831 MW
• Main steam Temp - 542

When the Plant is TRIPPED
•>.', un,y.
f 646 90
1439.61
A A
1332.31
f^ 1 r^2'.m
i
.Stcj/M>fi<i
\ t>n»« I ^-nA SP I'Ssoe®!"
-~i 29<S3-2S3i|;
T / r a r fiesjs^t' 5SJ,S1*» £-f;»t* jvprj«r/i rniT «j»^t«- 376,4%4fi
Jl*: \h-*e D«*i
Fig 4.9(d) Output Waveform
• Drum actual level : -463.2457 MMWC

• Steam flow : 185.9702 TPH
• Feed water flow : 52.5639 TPH
• Output load : 0.2475 MW
• Main steam Temp: 548 C

5.2 CONCLUSION
Boiler Drum Level Control based on the set values of low level and high-level
supervision properly for performance improvement of steam temperature and water level
processes. Data collected with the 3-element PID control scheme was used for drum level
control.
In a boiler drum, there is a probability of underflow or overflow of water level has in the
drum by change of set point controlled efficiently with PID controller action. 3-element
control loop has been taken up for boiler drum level.
• Three parameters taken for controlling Drum Level with corresponding

transmitters and set values to PID Controller for controlling the processes.
• The steam temperature is greatly improved by controlling the primary and

secondary super heating spraying processes.
• Feed water from Deaerator control with PID Control action, controls the speed
of Turbine Driven Boiler feed pumps (TDBFPs), so efficiently and
automatically control the drum level with the MaxDNA.

REFERENCES
[I] www.ntpc.co.in/ramagundam
[2] http://www.en.wikipedia.org/thermal_powerstation.htm
[3] www.ccivalve.com
[4] www.tycoflowcontrol.com
[5] Boiler drum level control/yokogawa.pdf
[6] ntpc/library/unit-7 manuals
[7] http://www.pc-education.mcmaster.ca/default.htm
[8] Logic diagrams referred from NTPC unit-7 manual
[9] BHEL EDN and Metso Automation MAX Controls, Inc.USA/reference
[10] Anderson, T.; Mei Feng; Riddle, S.; Romanovsky, A, "Error recovery for a
boiler system with OTS PID controller", IEEE International Workshop, vol 10,
pp.113-120,2005
[II] Xiaobin Huang; Hongjing Qi; Xuan Liu, "Implementation of Fault Detection
and Diagnosis System for Control Systems in Thermal Power Plants," the sixth
world congress, vol 2,pp.5777-5781, 2006
[12] Wei Wang; Han-Xiong Li; Jingtao Zhang, "Intelligence-based hybrid control
for power plant boiler," IEEE Trans. Control system technology,
vol.l0,pp.280-287, 2002
[13] Hugh F. VanLandingham and Nishith D. Tripathi, "Knowledge-based

Adaptive Fuzzy Control of Drum Level in a Boile^^steni", IEEE
conference papers, pp.454-459, 1996
Boiler Drum Level Control in TheranS-Bower P l a n t / W / 81

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A DISSERTATION REPORT ON

"^BOIUR DRUM UBVEL CaiiTROL IBT

Submitted in partial fiilfiliment of the requirement for the Award of the

Under the esteemed guidance of

Dr. ASHAVANI KUMAR

NATIONAL INSTITUTE OF TECHNOLOGY

This is to certify that the project entitled "BOILER DRUM

Internal Supervisor External Supervisor

Dr. ASHAVANI KUMAR SUBRAHMANYAM CVB

2 Process and Description of Logic Diagrams 14 ,

2.2 Description of Logic Diagrams 24

Boiler Drum Level Control in Thermal Power Plant

Boiler Drum Level Control in Thermal Power Plant

Boiler Drum Level Control in Thermal Power Plant

Fig 1.1 Drum Level Control 4

Boiler Drum Level Control in Thermal Power Plant

Boiler Drum Level Control in Thermal Power Plant

Acronym Expansion of acronym

Boiler Drum Level Control in Thermal Power Plant

Boiler Drum Level Control in Thermal Power Plant 1

Boiler Drum Level Control in Thermal Power Plant

Ramagundam Super Thermal Power Station(2600 MW- ISO 9001, ISO

1.1.1 Drum Level Control:

Boiler Drum Level Control in Thermal Power Plant

'1 MJIH Last

(1.00» 83.33 *> aOO-s 86,71 %

I OR l,OAB FCV rOVM »BfP-f, «O0P COMTHOl.

KitM «*«].«» P«J8**t • MltA.e

Fig 1.1 Drum Level Control

Boiler Drum Level Control in Thermal Power Plant

1.1.2 MAIN STEAM TEMPERATURE AND WATER LEVEL SYSTEM:

The investigated boiler of a 500MW power unit is a compound circulatory tower

Boiler Drum Level Control in Thermal Power Plant 5

1.1.3 Control of Level with PID Controller:

Fig 1.2 (a) Control of Level with PID Controller

The following two key points:

Boiler Drum Level Control in Thermal Power Plant

1.2.1 BLOCK DIAGRAM OF DRUM LEVEL CONTROL:

Boiler Drum Level Control in Thermal Power Plant 7

Fig 1.2(b) Block Diagram

Total Feed Water Flow = Feed Water flow + Spray Flow

1.2.2 BOILER FEED PUMPS (BFPs) SPEED CONTROL:

Boiler Drum Level Control in Thermal Power Plant 9

1.2.4 Level Transmission Calibration:

Application of Level Transmitters:

Boiler Drum Level Control in Thermal Power Plant 10

Fig 1.3 Levels Transmitters to Drum

1.2.5 Differential Pressure Transmitters:

Boiler Drum Level Control in Thermal Power Plant 11

1.2.6 Flow Transmitters:

Fig 1.5 (a) Orifice flow meter

Boiler Drum Level Control in Thermal Power Plant 12

Ai, A3 = area of upward stream and down ward stream

Vi = Velocity of up ward fluid

Pi,P3 = Pressure difference

Cmeter= Discharge coefficient

Upstream pressure throat position down pressure

Fig 1.5 (b) Venturi meter

Boiler Drum Level Control in Thermal Power Plant 13

Boiler Drum Level Control in Thermal Power Plant 14

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