Digitally signed by U R KHOSLA

DN: cn=U R KHOSLA, c=IN, o=NTPC,

NOIDA, ou=EOC,
email=urkhosla@ntpceoc.co.in
Reason: Approved in Cat-Iv-refer
transmittal
Date: 2008.09.05 11:37:12 +05'30'
 NTPC / Simhadri STPP, Stage-II, 2 x 500
MW
RECOMMENDED AUTO CONTROL WRITE-UP

WRITE-UP ON BOILER AUTO CONTROL SYSTEMS

THE FOLLOWING CONTROL LOOP DESCRIPTIONS ARE COVERED IN THIS WRITE UP

Sl. Drg. Ref.

Description
No. (Sheet No.)

01 FEEDWATER CONTROL 2.1, 2.2

02 FURNACE DRAFT CONTROL 3.1,3.2

03 PRIMARY AIR HEADER PRESSURE CONTROL 4

04 MILL OUTLET TEMPERATURE CONTROL 5.1,5.2

05 COMBUSTION CONTROL 6

06 AIR FLOW CONTROL 7.1,7.2

07 FUEL FLOW CONTROL 8.1,8.2

08 AIR HEATER TEMPERATURE CONTROL 9

10.1,10.2,10.3, 10.4,
SUPERHEATER AND REHEATER STEAM TEMPERATURE
09
CONTROL 10.5

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01. FEED WATER CONTROL (DRUM LEVEL CONTROL)

The objective of this control system is to maintain the drum level to the normal water
level of the drum at all loads. At lower loads (less than 30% MCR), the start up feed
control valve will be used as final control element and at higher loads; speed control of
Boiler Feedwater Pumps (BFPs) will be used. Drum level is measured by transmitters
through temperature compensated constant head unit. The pressure compensated
drum level signal may be selected by Mid Value Auto Selection (MVAS) circuit for
control.

Low load: The drum level measured signal is compared with the drum level set point.
The error signal will have a proportional, integral and differential action in the single
element controller. This controller output will be the position demand signal for the
start up feed control valve. Auto/manual station is provided for auto/manual selection
and operation. Position indicator is provided for the start up feed control valve.

High load: At higher loads the start up control valve shall be closed. The steam flow
shall be measured. In order to prevent sudden response due to drum swell and shrink
on load change, a time lag unit shall be included in the steam flow signal. The
temperature compensated feed water flow signal is computed by adding feedwater flow
at economiser inlet and superheater spray water flow. The error signal produced
between drum level measured signal and drum level set point shall have proportional,
integral and differential action in the three-element drum level controller. This will be
added with steam flow signal, which is the feed water flow demand signal (set point for
feed water flow). This will be compared with the feed water flow in the feed water
controller. Deviation if any will have a proportional and integral action in the feed water
controller. This controller output will be the desired speed signal for the individual
Boiler Feedwater Pump (BFP) speed control system. Auto/manual station is provided
for auto/manual selection and operation. Position indicator is provided for the motor
driven BFP hydraulic coupling scoop position indication and speed indicator is
provided for turbine drive BFP speed indication.

02. FURNACE DRAFT CONTROL

The main objective of the control is to maintain the furnace pressure constant at the
desired set value at all loads. This is achieved by changing the flow of flue gas by
modulating the inlet guide vane or inlet damper and varying the speed of the ID fan by
variable frequency drive system. Furnace pressure is measured by three transmitters.
One signal is selected by mid value auto selection circuit for control. Excessive
furnace pressure is monitored for directional block on Induced Draft (ID) and Forced
Draft (FD) fans. Furnace pressure is compared with set point and error, will have
proportional and integral action. Fuel demand signal is added as a feed forward
feature. Master Fuel Trip (MFT) feed forward feature is provided to minimise negative
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furnace pressure excursion. Separate auto/manual station, and the position indicator
for each ID fan-regulating device is provided.

To have equal loading of the ID fans each ID fan motor current (sum of channel 1 and
channel 2 current) is measured averaged and compared. The difference is used for
taking corrective action. The corrected signal is used to position the ID fan inlet
damper. The ID fan inlet damper positions between a maximum and a minimum
position limit for optimised control action. If ID fan position goes outside these limits,
an error signal goes to a controller, whose output is used to vary fan speed to bring
back the inlet damper within the set limits.

Separate auto/Manual station and position/speed indicator are provided for each ID fan-
regulating device (damper/VFD)

03. PRIMARY AIR HEADER PRESSURE CONTROL

The main objective of this control is to adjust the primary air header pressure
according to the feeder speed. That is, out of all the feeders, the feeder speed, which is
higher than that of others, is considered as set value for this control.

Primary air header pressure is measured with three transmitters. One signal is selected
by mid value auto selection circuit for control. The measured signal is compared with
the selected feeder speed signal through a high signal selector to maintain the
minimum header pressure. Deviation if any will have proportional and integral action.
Separate auto/manual station and position indicator are provided for each Primary Air
(PA) fan-regulating device.

To have equal loading of two running PA fans, the PA fans motor current is measured,
averaged and compared. The difference is used for taking corrective action. The
corrective signal is used to position the PA fan-regulating unit.

Refer the 'notes' in the control scheme for the interlocks.

04. MILL OUTLET TEMPERATURE AND AIR FLOW CONTROL

The objective of this control system is to adjust the mill air flow according to the feeder
speed and to maintain the mill outlet temperature at the constant set value.

Mill airflow is maintained by adjusting the hot air regulating damper while the mill outlet
temperature is maintained constant by adjusting the cold air-regulating damper. The
temperature compensated linearised mill airflow signal is compared with variable
airflow set point as a function of feeder speed. Any error between these two signals
will have proportional plus integral action. Rate of change of fuel demand signal is
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added to provide feed forward feature. An auto/manual station with position indicator
is provided.

Mill outlet temperature is measured using a thermocouple with tungsten carbide

thermowell to avoid erosion. The mill outlet temperature is compared with constant set
point and error will have proportional, integral and derivative action. An auto/manual
station with position indicator is provided.

05. COMBUSTION CONTROL

The objective of this control is to maintain the turbine throttle pressure constant at the
desired value by adjusting the firing rate (both fuel flow and air flow).

Turbine throttle pressure is measured with primary and redundant transmitters.

Deviation is alarmed and the controller is tripped to manual. The selected signal is
compared with the set point and any error will have proportional and integral action. A
proportional value of total steam flow and derivative of drum pressure signal are taken
as feed forward feature for the control. An auto/manual station is provided. The output
of A/M station is the airflow demand and fuel flow demand signal.

Refer the 'notes' in the control scheme for interlocks.

06. AIR FLOW CONTROL

The secondary airflow is measured at left and right side of the secondary air ducts to
wind box by means of aerofoils. Each flow will have temperature compensation. The
flow is linearised by means of square root extractors. The total PA flow measured for
each mill in service, is added to obtain total airflow to the boiler. This signal is
compared with the developed set point. The airflow demand from coordinated control
and actual fuel flow whichever is high (lead lag system) is selected to ensure enriched
combustion air. The oxygen in the flue gas at the inlet of AH is measured as primary or
redundant. Transfer switch can be selected for either average value or individual value.
This signal is compared with excess air set point and any error will have proportional
and integral action to have better combustion efficiency. High/low limiters are used to
limit the value in case the oxygen analyser is out of service. Under any circumstance
the airflow should not be less than 30% MCR flow. This signal is the developed set
point and the airflow signal will have proportional and integral action in the airflow
controller.

This position demand signal will be selected to the corresponding FD fans in service
through' auto/manual station. To have equal loading of FD fans the FD fan motors
current is measured. The difference is used for taking corrective action. The corrected
signal is used to position the FD fan-regulating damper. Necessary interlock from
FSSS, Boiler auxiliaries interlock system Maximum Deviation Limit (MDL) etc. are
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provided. Separate auto/manual station and position indicator for each FD fan-
regulating device are provided.

Refer notes in the drawing for interlocks.

07. FUEL FLOW CONTROL

Fuel flow demand from combustion control and air flow signal from air flow control
corrected for fuel air ratio are compared and the lower is selected for the set point of
the fuel flow controller. (lead-lag system). This is to ensure that under any
circumstance the fuel flow should be lesser than the airflow.

Fuel flow is measured by adding the feed signal of the feeders (or mills) in service and
the heavy oil flow corrected for calorific value. The feeder speed/rate measured signal
is hooked up to the control after a delay to suit the process lag. The actual fuel flow
signal is compared with the developed set point signal above and any deviation will
have proportional and integral action. The controller's output signal is the position
demand signal for feeder speed regulating device. Bias unit is provided to modify the
signal whenever required. An auto/manual station is provided for each feeder.

To ensure air rich furnace at all times, a maximum deviation limit system (MDL) is used.
i.e. Whenever the fuel flow is more than the air flow this will automatically reduce the
fuel flow and increase air flow to a safe value and both the air flow and fuel flow control
is transferred to manual.

Refer the 'notes' in the control scheme for interlocks.

08. AIRHEATER TEMPERATURE CONTROL

The control basically consists of the following two interrelated control systems.

A. Cold end temperature control.

B. Hot gas damper control.

SCAPH steam flow control

The purpose of this control loop is to maintain the cold end temperature above the dew
point thus preventing condensation and resultant corrosion of airheater surfaces. The
cold end temperature of AH. i.e. AH air inlet and AH flue gas outlet temperature is
measured and averaged. The average temperature is compared with the set point and
any deviation will have proportional and integral action. An auto/manual station with
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position indicator is provided. The operation of this control may be required while
lighting up the boiler. The steam valves are automatically slowly closed if the
measured cold end temperature is approximately at setpoint value and the associated
hot gas damper is not fully open. This improves the overall efficiency by allowing the
hot gas damper instead of the steam valve to raise the cold end temperature when
possible.

Refer the 'notes' in the control scheme for interlocks.

Hot gas damper control

This loop is used to equalise primary and secondary airheater gas outlet temperatures.
This serves to reduce gas temperature imbalances (stratification) at ID fan and
increases unit efficiency. In the automatic mode, average primary and secondary air-
heater gas outlet temperatures are compared and the resulting signal is received by a
PID controller. The controller output is received by two function generators, whose
output determine damper position. A limit is provided to maintain damper operator
between a specified minimum and full open position. An alarm is activated if dampers
reach their minimum position. When a temperature difference is sensed, the controller
output will change and the damper controlling the hotter gas outlet will begin to close
while the damper controlling the colder gas outlet remain open. (See function generator
on the reference drawing) the resultant redistribution of hot gas will serve to equalise
the outlet temperatures. With this scheme one damper (that controlling the colder
outlet) will always be fully open while the other damper modulates between its
minimum and full open position. In manual control, dampers are to be initialised by the
operator at 100 % open position. A signal indicating that both dampers are fully open is
to be interlocked into the ID fan start logic as a start permissive. Transfers are
designed to be bumpless. If control power is lost dampers are to lock in position or to
be forced fully open.

Refer notes in control scheme for interlocks.

09. SUPERHEATER/REHEATER STEAM TEMPERATURE CONTROL

General

Steam temperature control is provided by a combination of burner nozzle tilt

positioning and Superheater (SH), Reheater (RH) de-superheating spray. Steam
temperature is maintained by allowing nozzle tilt to respond to the lower of either SH or
RH outlet temperature, with spray responding to the higher. Auto manual stations are
to be provided for modulating the following
1 SH spray water valve - left
2 SH spray water valve - right
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3 RH spray water valve - left
4 RH spray water valve - right
5 Burner tilt power cylinder.

Each measurement is manually selectable between a primary and redundant element.

Each pair of elements is compared and excessive deviation between the primary and
redundant is alarmed, with control transferred to manual.

SH spray water valve control

In the automatic mode, each SH spray water valve is controlled by a cascade control.
Under normal conditions average SH outlet temperature (Tsho), the primary controlled
variable, is in the outer loop of the cascade control for each valve; SH Desuperheater
(DESH) outlet temperature (Tshdso), an index of the immediate effect of spray valve
operation, is in the inner loop. The outer loop PID controller receives an error signal
equal to the average deviation of Tsho set point and each measured final SH (left and
right) outlet temperature (Tshol and Tshor). The Tsho set point is programmed as a
function of unit steam flow for constant pressure operation (or sliding pressure
operation). The outer loop controller establishes a set point for the SH DESH outlet
temp. This set point is compared to measured Tshdso and the resulting error is used
to position the SH spray valves.

If the deviation between Tsho set point and measured Tshol or Tshor exceeds a preset
high limit, control of the outer cascade loops is transferred from average Tsho to the
individual final SH outlet temperature, Tshoa and Tshob. Strong feed forward to the SH
temperature control which interact with each other are provided. These feed forwards
are needed to compensate for over firing and under firing which may be required
initially. When changing unit load, feedforward signals are utilised as follows (using
unit load increase as an example):

1. The rate of change of fuel demand increase (an indication of over firing) is used to
open the SH spray valves to counter the initial temperature rise.

2. Drum pressure and steam flow (applied inversely) to spray valve demand) and tilt
position (applied directly) are used as an index to recognize the tendency for temp. to
drop after item-1 above occurs, and is used to close the SH spray valves to counter the
subsequent temperature drop.

Interlocks are provided to close the SH spray valves at loads less than 20% MCR.

RH spray water valve control

In the automatic mode, each RH DESH spray water valve is controlled by a cascade
control. Under normal operating conditions RH outlet temperature (Trho), the primary
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controlled variable is in the outer loop of each cascade control; RH DESH outlet
temperature (Trhdso), an index of the immediate effect of spray valve operation, is in
the inner loop.

The outer loop PID controller receives an error signal final RH (left and right) outlet
temperature (Trhol and Trhor). The Trho set point is programmed against the main
steam flow curve, for constant pressure operation (or sliding pressure operation). The
outer loop controller output is modified with tilt position to establish a set point for the
RH DESH outlet temperature. This set point is compared to measured Trhdso, and the
resulting error is used to position the associated RH DESH spray water valve.

If the deviation between the Trho set point and the individual measured final RH outlet
temperature exceeds a preset high limit, control of the outer cascade loops is
transferred from average Trho to the individual measured final RH outlet temperature
(Trhol and Trhor) to allow spraying of the hot lead.

Interlocks are provided to keep the spray valves closed at loads less than 20% MCR.

Nozzle tilt control

The average Tsho and Trho error signals are compared and the greater of the two
errors (i.e., the lower of the two temperatures) is selected for nozzle tilt control. An
interlock is provided to keep the tilts at their base (horizontal) position at loads less
than 25% MCR. If any spray water valve opens fully, the tilt control is interlocked to
disallow further raising of the tilts, and thus prevent possible over heating of the SH
and RH outlet lead.

Refer notes in control scheme for interlocks.

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