ANALOG CONTROL SYSTEM

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ANALOG CONTROL SYSTEM

In power plant industries, the four basic variables namely Pressure, Temperature,
Level, and Flow of the process media needed to be continuously controlled for
maintaining them within desired /required limits .Solid state electronics based Analog
control system is provided in the plant for controlling various process variables (e.g.
main steam pressure ,temp, flow drum level, air flow etc.)at desired value. In this type
of control system analoge electrical signals (4 -20mA) are generated to represent the
value of process variables using primary elements /transducers. These signals are
conditioned and transmitted to electronic control system for further processing.
Output of this system is used to activate the final control element e.g. control valves,
dampers, guide vanes etc. so as to maintain the process variables at desired set point.
This system is called Analog Control System because throughout the control starting
from monitoring to conditioning ,to processing and till operating the final control
element there exists a definite analogy between the input and output of various
subsystems (i.e. transducer, transmitter etc.).Here the signals being processed /used
for control are nothing but physical quantities current ,voltage etc. which are similar
to the process variables being controlled. It is totally different from digital system
wherein ,instead of physical quantities, discrete numbers are used for processing. It is
necessary that all the parameters should have optimum values throughout the range
of unit operation. For having control on parameters of various subsystem several
control loops are in service with specific objectives. Description of following important
control loops is covered here under : 1.

Hotwell level control

2.

Drum level control / Feed water control

3.

PA header pressure control

4.

R/H temperature control

5.

SH temperature control

6.

Draft control

Acs has got two operating channels which are simultaneously active i.e.
Teleperm - M & Teleperm - C
Teleperm C - is the control system which is purely hardware based electronic wherein
controls all the related logics & computation are done through electronic
cards/modules only.
Teleperm M - This the control which uses software in addition to hardware electronic
cards. Wherein part of the computation logics are performed through software. During
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normal operation if Tel. C fails for a particular system, that control will transfer to Tel
M automatically however reverse is not possible. Selection of any of these two channel
can be done from UCB depending on the healthiness of control system.
Hotwell Level Control
Condenser hotwell level shall be controlled by regulating the make up water flow to the
condenser. The make up to condenser is primarily provided through the make up line
from demineralisation plant. If the condenser make up demand exceeds the flow in
DM water make up line ,the additional requirement of make up water shall be
supplied from condensate storage tank. Accordingly ,the low level in hotwell shall be
controlled by modulating:
(a)

Normal make up valve in DM water make up line.

(b)

Emergency make up valve in emergency make up line from CST.

Hotwell level control system is provided with three separate controllers termed as
Hotwell high level controller, Hotwell normal level controller and Hotwell low level
controller. For high level and normal or low level there are two separate level
transmitters. In all the three controllers actual Hotwell level is measured through
level transmitters, Output of which is inturn converted into corresponding current
signal and then voltage signal through two converters .The available voltage signal is
compared with Hotwell level set value in terms of voltage. Net available voltage is fed to
a PI controller and output of this used for opening or closing of respective pneumatic
control valves provided for Normal, Emergency or spill control thereby controlling the
makeup flow as per the demand. Actual position feed back of the valve is available in
the UCB. Control circuit is provided with hard hold memory card which retains the
last available value and provides smooth change over to manual whenever auto control
fails.
Auto control fails giving a flashing lamp on the controller module when actual level
goes beyond the level transmitter range.
Drum Level Control / Feed Water Control
This control loop is used for controlling of drum level. Depending on the feed water
flow path two separate control loops are used.
Namely, single element control & three element control.
Single element control :- This control system gets selected when BLI(Boiler load
index)is below < 20 % and feed water flow is controlled through low range line. In this
control system actual level of drum, after pressure correction, is compared with the set
point and available net voltage is processed through a PID controller. Output of this
controller is used for generation of pneumatic pressure for actuation of low range feed
water control valve. Actual valve position is displayed in UCB. If running BFP
scoop/speed is kept on auto it will slowly bring the speed to a constant value which is
already preset in the control system and the feed flow will be controlled through
pneumatic control valves.
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Three element control :- Three element control is selected for higher load operation.
In this control the feed flow is controlled by varying BFP speed. The set demand for
scoop is achieved as follows Actual drum level and set point difference, after taking into account input of BLI, is
compared with sum of feed water flow & SH spray flow signal . The net resultant
output is fed to a PI controller and subsequently the output of feed master controller
sets the speed demand for TDBFP and MDBFP.
Primary Air Pressure Control
It is needed to maintain sufficient primary air pressure under all condition as this is
essential for carrying coal from pulveriser to furnace. Under this control system
actual pressure developed by PA fans is converted into voltage and is compared with
the set voltage (in terms of PA header pressure)then the net available output is
separately processed through two PI controllers meant for individual control loop, the
output of these controllers is used to set the demand position of blade pitch of each
fans. Actual position of blade pitch is available in UCB. Moreover biasing is provided
for adjusting the loading between two fans. Control loop includes following interlocks
1.

Control system is released for auto operation only after outlet damper has opened
fully.

2.

Control system switches to manual when fan is stopped.

3.

Blade pitch operation is blocked on control oil pr. LO. LO.

Reheater temperature control :

Reheater temperature control is achieved through burner tilt and spray. In the
process of reheat temperature control, it is ensured that burner tilt operates first for
bringing down the temperature and after certain time spray comes in service, likewise
when reheat temperature is going down then first spray is cut-off and thereafter
burner tilt is operated.
Reheat temperature Control system consists of two Thermocouples one each for left
and right reheat temperature measurement. For generating temp. demand set point
,output of a function generator, based on BLI and output of a manual setter on the
control desk, are fed to a minimum selector. Minimum of these two signals is used as
final temp. set point for burner tilt. The set point for spray control can be given with a
bias from the panel itself in the range from 0 to 50c. Biasing between left and right
spray valve is also provided which can be set from panel.
Spray block valve will close if control valve opening becomes less than 5 %. In the
control system actual reheat temp is compared with set value for temp and output is
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processed through separate PID controllers for spray control & the demand position of
spray valve and burner tilt. Demand position of RH spray valves are displayed on the
panel and average tilt position along with the position feedback of all the four corners
tilt position is shown separately on UCB panel.
SH temperature Control
In this control system SH steam outlet temp. is maintained at set point which is equal
to the minimum of
(1)

set point manually set from UCB.

(2)

Set point derived through a function generator based on BLI (Boiler Load Index).

Thus derived temp. set point is compared with signal corresponding to actual main
steam temp. measured through thermocouple at SH outlet. Separate comparison is
done for SH left and right streams . Error signals thus developed are further
influenced by feedforward signals from burner tilt position and BLI.
These corrected error signals are now compared with respective error signals derived
by desuperheater control loop and the final error signals are given as input to two
separated PID controllers ,one each for left and right streams, for finally controlling
the superheater spray through pneumatically operated control valves. The controler
output is displayed in UCB. An interlock is provided for closing the inlet block valve
below 5% opening of control valves..
Co - ordinated Control System :
As electrical energy cannot be stored in a large quantity it is necessary to balance its
generation with momentary consumption. The grid frequency is the factor which
indicates the degree of balance between production (generation) and the consumption.
In absence of storage capacity for electrical energy it is a must for a modern power
plant to have adequate control system to respond to rapid load changes and at the
same time control the process/the equipments so that no part of the plant runs into a
dangerous operating state i.e. the pressure, temperature and other process
parameters must not cross the designed/safe limits of a particular equipment ,
otherwise, the availability and required safety of the man and machine will be
reduced / endangered.
In order to achieve best efficiency and best availability with requisite safety, it is
necessary that operation of both the main plant equipments ( i.e. Boiler and Turbine)
is co-ordinated using suitable control system and there should be a possibility of
decoupling them during disturbances by means of bypass system.
Boiler and Turbine have a number of equipments which must be able to follow their
demands during unit start-up / shutdown and load variations. As a result, the power
plant process has a hierarchial structure and in order to match with the process best
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the control/automation concept adopted is also hierarchial. A typical scheme is shown

in following block diagram.
The above hierarchial control concept is implemented through Teleperm C &
Teleperm M series of Siemens AG, WG make control system in case of Singrauli
500MW units. As the 500MW Simulator is designed as replica of Singraulis 500MW
unit, the control system of the same is taken as base for discussion here. However, the
general philosophy is similar to hierarchial control systems of other projects.
A simple scheme of control system for unit co-ordination is shown in drawing.
Depending upon various conditions/limitations of the plant equipments, different
control configurations/modes are selected to carry out the unit co-ordination function.
Followings are the four basic operating modes available in the control system : Co-ordinated Master Control (CMC) Mode
Boiler Follow Mode (BFM)
Turbine Follow Mode (TFM)
Run Back Mode
The basic task of achieving balance between energy generated (supply) and its
instantaneous consumption (demand) calls for generating a load set point depending
upon instantaneous grid demand and permissible/allowable limits/conditions of the
various plant equipments at that moment. This is called Target Load Set Point. This
set point is used as guidance signal for monitoring/controlling various plant
equipments/process parameters to accomplish the desired task of energy balance.
The process of generating this target load set point guidance signal is discussed in
following section along with four modes of unit co-ordination . Working philosophy of
some of the important individual control loops of the hierarchial control system is
already covered under Analog Control System above.
Generation Of Load Demand Signal
Load Demand is the MW set point signal for boiler combustion control and turbine
(EHC). This signal is generated as follows:
Target Load (MW set point) for the unit is set either by UCB operator or in auto mode
from load despatch centre. Digital display is provided for target load. This target load
is subject to MIN & MAX Limits, set by the UCB operator. After this limiting, target
load is subjected to a rate control which various the MW set point signal at the rate set
by the UCB operator or as permitted by the TSE whichever is lower. In CMC both
turbine and Boiler Master (BM) are on auto hence the input to the rate controller
(Known as SPCM) will be the target load set point. To this rate controlled set point a
frequency influence correction signal is added and Load Demand signal is formed.

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To ensure that the unit is following the load set point closely, an inhibit increase /
decrease feature is provided. If any of MW, Throttle steam pressure, FW flow, Fuel
flow & PA Header pressuredeviates from set point significantly or has reached the
MAX/MIN limits, the load demand is inhibited from increasing or decreasing as the
case may be. Air flow & turbine load limit active are two additional signals to inhibit
increase of load demand.
Boiler master and generation of fuel / air set point:
The function of the boiler master auto / manual station in CMC Console is to provide
a set point for fuel and air flow i.e. fuel demand and air demand signals. In Coordinated mode, it is equal to sum of boiler load set point and master controller (PID)
output. In this mode Boiler master controller acts on DP error. The fuel demand as
generated is compared with actual air flow and a minimum of the two is selected as
the fuel set point.
The air demand as generated is compared with fuel flow & 30 % of air flow and
maximum is selected as air set point. This MIN/MAX selection ensures an air rich
furnace. When fuel/air demand increases the MAX gate first increases the air set
point and when fuel demand decreases the MAX gate permits reduction of air flow only
after fuel has decreased.
Fuel Flow control :
Oil flow to burners and feeders speed (which is the measure of coal flow) along with
Calorific Value(C.V) corrections added to get total fuel flow. Cabinet adjustments are
provided to take care of individual calorific values to obtain total fuel flow as fuel oil
equivalent (FOE). The total fuel flow (FOE) is compared with fuel set point to
generated fuel control error. This control error is fed through (Pl) controller (Master
Fuel Controller) to all feeders in auto and Each feeder is provided with a bias and an
auto /manual station.
Secondary Air Flow Control
As mentioned earlier, air demand is generated as the MAX of the following:1)

Air demand from Boiler Master

2)

Air flow as calculated based on actual fuel flow

3)

A safe minimum 30 % air setting

At SSTPS secondary air flow is measured by aerofoil near the windbox (left & right) by
two transmitters, sum of the two transmitters give the secondary air flow. Primary air
flow is added to this to give total air flow which is used for combustion control, purge
logic & SADC (Secondary Air Damper Control). This actual air flow is compared with
the air set point and then modified by O2 trim to generate the air flow control error.
This signal is doubled in case only one, out of two running fans available for automatic
control. An equalising and biasing signal is added to equalise and bias the individual
fan air flows. Control signal thus formed operates on the individual controller (for

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each fan) whose output fires the thyristor drives of the 415 V AC motors for blade
pitch control. An auto / manual station is provided for each fan.
O2 TRIM
A selection station and a setter for oxygen set point are provided to achieve the desired
excess air. If variable O2 set point (SP) is selected, set point is generated by a function
generator which is a function of MAX (air flow SP and total air flow). In other mode SP
is set from UCB. O2 in flue gas is compared with this SP and error is fed to PI
controller, output of which is limited between 0.8 and 1.2 times of total air flow. O2 PI
controller output is now multiplied by total air flow and the resultant O / P signal is
given to makes the FD fans blade pitch controllers for achieving desired air flow. O2
probes are provided at the outlet of economiser for measurement and control of the
flue gas O2. These probes are zirconium oxide probes working on the principle of
partial pressure of oxygen.Thus the input signal to FD Fan blade pitch controllers is
trimmed by O2 signal to get desired Excess air / O2 set point
Generation of DP / DMW Signals
The pressure set point compared with actual throttle steam pressure to obtain the
control error signal DP. Three pressure transmitters are provided for redundancy
along with deviation monitoring and middle of the three is selected as actual pressure.
In case of two transmitters fault, the control is put to manual. The pressure set point
generated in this circuit is also sent to HP Bypass Control. Actual MW signal (middle
value of O/P of 3 transducer) is sent from turbine control panel to CMC console where
DMW signal is formed as the difference between load demand and actual MW.
Selection of CMC
1.

Put Air Master on Auto i.e. atleast one FD fan blade pitch controller on auto.

2.

Put feeders speed control on auto after varying Fuel Master (FM) output and
making feeder speed controller error zero.

3.

Vary Boiler Master Output so that FM error becomes zero. Then put FM on auto.

4.

Make throttle pre. set point and actual pr. difference zero .

5.

Put BM on auto

6.

Increase / decrease unit master output so that it becomes equal to actual load.
(wait until load set value and load actual value matches as shown in the CMC
console digital indicator)

7.

From Turbine desk put turbine control on auto.

8.

Press co-ordinated push button along with manual release on CMC desk.

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Boiler Follow Mode

In this mode turbine is in manual and the load is set at the turbine desk. The boiler
in auto follows the turbine and fires to maintain the throttle pressure. It means boiler
master has to be on Auto. If for any reason or other,the load demand set point signal
is not available the turbine load has to be set manually and the system can be
switched to boiler follow mode. In Boiler follow mode, set point = sum of boiler load
index and Master controller output (PID) acting on DP.
In Boiler Follow Mode as turbine is on manual so input to SPCM will be turbine load
set point. .
Selection of Boiler Follow Mode :
1)

Put Air, FW & Fuel Master Controller on Auto.

2)

Put Boiler Master Controller on Auto.

Note

: While putting any controller on auto ensure corresponding error signal

is zero.

If the unit is in co-ordinated mode automatic change over to Boiler Follow Mode occurs
under following conditions
a)

Turbine goes to manual because of any reason.

OR

b)

(PrCMC - Pr lim) > 60 MW [i.e. when difference between set point guidance signal
and load set point for EHC is more than 60 MW ]

Turbine Follow Mode

It means turbine control has to be on Auto. On turbine follow mode the unit load is
controlled through boiler, acting on the firing rate in the same manner as the steam
pressure control described in CMC mode. The pressure is controlled by Pr.controller
of EHC utilising the pressure deviation formed in the boiler master control system. In
turbine follow mode turbine operates in initial pressure mode.
In TFM set point = Sum of boiler load set point and master controller output (acting
on DMW Error)
Selection of Turbine follow mode:
1)

Boiler master on manual

2)

Confirm that throttle pressure deviation is zero

3)

Put turbine in Auto from turbine desk

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4)
Press Turbine follow push button along with manual release on CMC desk and
turbine goes to
initial pressure mode from limit pressure modes by itself.
5)

Now load set point can be changed by varying the boiler master manually.

Runback Mode
Under runback condition the firing rate for the boiler must be reduced to pre-set
values, as close as possible to the tolerable limits. Therefore the swings of firing rate
caused by the action of the PID controller must be avoided. As consequence of this
condition the system has to be switched to pure feed forward control, where the firing
rate set point is directly proportional to the load capability signal. To avoid any
mismatch between steam production of the boiler and the turbine load, the turbine
has to be switched to initial pressure control, as with TFM.
Runback Resetting
1)

Let the boiler master be in auto

2)

Reduce load set point from the turbine desk to a value slightly less than Unit
capability so that 1 0 Runback in Operation resets.

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