Control & Automation

For
Super Critical Units
K.S. Sundaram
NTPC, SIPAT
1

Introduction

Requirements

Comparison of Auto loops -Sub Critical Vs Super Critical

Feed Water Control

Steam Temperature Control

Unit Control

Turbine Control

Discussions

Super Critical Units

Increased requirement of accuracy and resolution of DDCMIS

systems.

No drum, hence no energy reserve.

Smooth changeovers between wet to dry operation and vice

versa

Control system should ensure smooth steady state operation.

Need to match fuel ,air and feed water accurately.

Stringent requirement of temperature controls as unbalance in
fuel and feed water has significant change in temperatures.

Little need for operator intervention.

Source :KEPRI

Source :KEPRI

Source :KEPRI

Comparsion Of Major Loops

Name of the loop

Remarks

SIPAT 660 MW

Furnace Draft

No major difference

Blade pitch control, Hydraulic

Air flow control

No major difference

Blade pitch control, Hydraulic

PA Hdr. control

No major difference

Blade pitch control, Hydraulic

Fuel master

Cross limiting from FW

VFD in feeders

FW control

Saturation Temp Controller

TDBFP 2 X 65%,
MDBFP 2X30%

SH temp control

FW plays a major role

FW plays a major role (Trip at

Temp >565 Deg)

RH temp control

No major difference .
Spray Should be Zero

Two tilts per corner (Trip at

Temp>580 Deg)

List Of Loops For Discussion

S.N. Name of the loop

Sub loops

01

Feed Water control

Feed Water Master

BCP / UG valve
FWPCV control
Separator Drains control

02

Super heater temp

control

Platen SH temp control

SH steam temp control

03

RH steam temp
control

Burner tilt control

Spray valves control
8

Feed Water Control Requirements

Ensure feed water flow in relation to unit demand.
Adjust feed water flow to get the desired separator outlet
temperature and degree of super heat.

Ensure the rangeability of platen SH spray valves

Ensure protection for Fuel /FW ratio.

Incorporate the start up level demand.

Ensure minimum required feed water flow.
Convert the flow requirement into pump demand with
compensation for pump capacities.
Ensure the pumps are within the operating range.

Final Control Elements In FW Loop

Control Element

MDBFP
SCOOP/TDBFP
Speed

BC Pump
Discharge Valve

Initial Condition Till

Chemical Parameter Is
Achieved Before
BC Pump Start

Condition From BC
Pump Start / BLU
Up To Load < 30 %
WET MODE

Load > 30 %
DRY MODE

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

Separator
Level control

Feed water flow

control

Feed water flow

control

--

--

Feed water
Valve ( Eq. to
30% Valve )

FW pressure control at
upstream of valve

FW pressure
control at
upstream of valve

Full open and

bypass valve opens

Separator Drain
Valves WR/ZR

Separator
Level control

Separator Hi
Level

--

10

Feed Water Master In Wet Mode

ACTUAL LEVEL

SEPARATOR LEVEL SETPOINT

SUB
10

PID

LEVEL SETPOINT

SEPARATOR
LEVEL SET
POINT FROM
ULD

8
6
Series1

4
2
0
0

100

200

300

400

ULD

TO BFPS

ULD
SP

0
9

300
3
11

Min FW Flow Control In Wet Mode

MIN. FW FLOW
SET POINT

FW FLOW TO
ECONOMISER

SUB
DP ACROSS BC
PUMP

PID

DP SET POINT
ACROSS BC
PUMP

SUB

PID

<

BC PUMP WILL TRIP IF DP

UG VALVE

IS < 4.5 Kg/Sqcm

12

FWPCV Valve Control In Wet Mode

BFP HEADER
PRESSURE
TRANSMITTERS

SEL
HIGHEST OF TDBFP
SUCTION FLOWS

SUB

HIGHEST OF MDBFP
SUCTION FLOWS

FG

FG

>

PID

FWPCV
13

Separator Drains Control

MEASURED SEPERATOR LEVEL

F(X)

WR

F(X)

ZR
14

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 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

15

Wet Mode & Dry Mode Of Operation

Source: Doosan

16

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.

17

FW Master In DRY Mode

BMD

SEPERATOR
OUT STM TEMP

PLATEN SH DT

BOILER MASTER
DEMAND

DSH

SEPERATOR OUTLET
TEMP SET POINT

SEP

F2(x)

F1(x)

PI

FG

NOT DRY MODE

SET TO ZERO

PI
FF SIGNAL

ANY SCANNER FLAME

(AND) BCP OFF

0%
A
a

>

TOTAL FW FLOW

FWF

F(x)

T2

30 %
A

FB SIGNAL

PI

Source : KEPRI

TO BFPs

18

Platen DSH DT Set Point

DT SETPOINT IN FW LOOP

DT SETPOINT

30
25
20
15

Series1

10
5
0
0

50
BOILER MASTER

100

BM(%)

DT

0
28.8
43.3
52.1
70.7
91
100

0
11
28
22
9
9
11

19

Source : EMERSON

Source : EMERSON

Source : EMERSON

22

Runbacks /Rundowns/Protections
Runbacks /Rundowns

Two TDBFPs 120%

One TDBFP + One MDBFP 95%
One TDBFP 65%
One MDBFP 30%
Rundown if FW deviation is high
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 ( 440 T/Hr)

Vertical wall tube metal temperature Hi Hi (4/48) (479 Deg)
MS / RH STEAM temperature Hi Hi 565/580 Deg
All BFP off for 20 Sec

23

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.

24

Final DSH DT Set Point

DT SETPOINT FOR FDSH

DT SETPOINT

30
25
20
15

Series1

10
5
0
0

50
BOILER MASTER

100

BM(%)

DT

0
28.8
43.3
52.1
70.7
91
100

0
27
21
18
7
7
7

25

SH Temperature Profile

DIV SH

406

451

PLATEN SH

440

FINAL SH

480

486

DSH1
15%

540

DSH2
3%

26

Source : KEPRI

27

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.

28

Source : KEPRI

29

RH Temperature Control (Tilt)

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

30

Source : KEPRI

31

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.

32

Source : KEPRI

33

34

Source :KEPRI

Source : EMERSON

Source : EMERSON

Turbine Control

Speed Loop- Till synchronization (IP Rolling)

IP is Throttle governing & HP is Nozzle governing

Open load loop till HP is charged
Pressure Control when HP is charged
Sliding Pressure Operation from 90 to 247 Kg/sqcm
Achieve full load & put on CMC

Salient Features:
Individual EHC for individual valves
No Hydraulic back up operation

37

HP BP Control

38

LPBP Control

39

References
KEPRI logics
EMERSON Logics

40

THANK YOU
41

FEED WATER PATH INITIAL STAGE

Back

VERTICAL WW
SEPARATORS

F
W
R
S

STORAGE TANK
ECONOMISER

ECO I/L

W
R

F
L
A
S
H
T
A
N
K

HPH

ZR

CONDE
NSER

CEP

LPH

DA

42

Back

FEED WATER PATH - LOAD < 30%

VERTICAL WW
SEPARATORS
S
T
O
R
A
G
E

HPH

T
A
N
K

ECONOMISER

ECO I/L

MIXING PIECE

BCP

UG
43

Back

FEED WATER PATH LOAD > 30%

S
E
P
A
R
A
T
O
R

S
E
P
A
R
A
T
O
R

VERTICAL WW

HPH

ECONOMISER

ECO I/L

TO BACKPASS
CONNECTING PIPES

44

45

CCP Auto Start And Auto Stop Conditions

Source :Doosan

46