Boiler Control Loops

Sumanta Basu
 Boiler Control Components

Burner Management/Boiler Protection

System(BMS/BPS )

Open Loop Control or Sequence Control ( SEQ )

Close Loop Control or Automatic Plant Control ( APC )

Automatic Plant Start up / Shutdown System ( APS )

L&T MHI Koradi Super Critical Boiler Parameters
Parameter Measuring Unit 100% BMCR
FW Flow kg/hr 2151,157
FW Pr. kg/cm2 (g) 311.01
FW Temp. °C 310.6
MS Flow kg/hr 2151,157
MS Pr. kg/cm2 (g) 255
MS Temp. °C 569
RH Flow kg/hr 1748,710
CRH Pr. kg/cm2 (g) 57.5
CRH Temp. °C 339.4
HRH Pr. kg/cm2 (g) 55.6
HRH Temp. °C 595
L&T MHI Koradi Super Critical Boiler Parameters
Parameter Measuring Unit 100% BMCR

Coal Flow kg/hr 399,774

Coal GCV (Design) Kcal/kg 3731

Coal GCV (Worst) Kcal/kg 3500

SA Flow kg/hr 1655,575

SA Pr. (Discharge) mmAq 330

PA Flow @ design coal kg/hr 610,024

PA Pr. (Discharge) mmAq 1165

Flue Gas Temp. (@ ID fan Inlet) °C 142

Major Closed Loop Control in Boiler (APC)

Unit Coordinated Controls

Feed Water Flow Control

WSDT Level Control

HPTB Control

MS Temperature & RH Steam Temperature Control

Fuel Flow Control & Air Flow Control

MRS Speed Control

Water Fuel Ratio Control

Furnace Draft Control

Wind box Damper Control
 LMB-SC Boiler Control
Local
Local
Model
Model N
1

Load Signal
Local Mode
Set Point Boiler Turbine Output
GPC Controller
U(t) Plant
Sequence Logic for Boiler Auxiliary Equipment

Air Heater (RAPH)

Induced Draft Fan (IDF)

Forced Draft Fan (FDF)

Primary Air Fan (PAF)

Seal Air Fan ( SAF)

Boiler Clean-up Sequence

RAPH Start Permissive

ESP Inlet/Outlet Dampers Open

Both FDF Off OR APH Dampers [below] Closed

APH Outlet 2ry Air Damper Close

APH Inlet Gas Damper Close

APH Outlet Gas Damper Close

Related FDF Available

Any CCCWP On

Air Heater (RAPH) [Protection Stop]

Emergency PB Operated
Induced Draft Fan (IDF) Logic
Induced Draft Fan (IDF) [Start Permissive]

IDF Inlet Damper Close

IDF Outlet Damper Open

IDF Blade Angle Min. Position

Control Oil Pressure > 700 kPa

Any Control Oil Pump ON

Any Lube Oil Pump ON

Any Seal Air Fan ON

Any CCCWP ON

IDF Radial Bearing (DE) Temp. < 85°C

IDF Thrust Bearing (NDE) Temp. < 85°C

IDF Radial Bearing (NDE) Temp. < 85°C
Induced Draft Fan (IDF) [Start Permissive]...cntd

Lube Oil Temp. in Tank between 15°C & 50°C

Control Oil Temp. in Tank between 15°C & 50°C

IDF Lube Oil Flow Normal [>17.5 l/min]

IDF Motor Oil Flow to Bearing (DE) Normal [>6.8
l/min]

IDF Motor Oil Flow to Bearing (NDE) Normal
[>6.1 l/min]

ESP Inlet & Outlet Dampers Open

DP between IDF Diffuser Inner Tube and Flue
Gas Air Duct > 250Pa
Induced Draft Fan (IDF) [Start Permissive]...cntd

Below conditions are also required to start Air &
Gas Draft Group in Auto

Both Air Heaters ON ( To start 1st IDF )

1st FDF ON (To start 2nd IDF)

Scanner Air Fan ON (To start 2nd IDF)

Total Air Flow > 15% (To start 2nd IDF)
Induced Draft Fan (IDF) [Protection Stop]

Both Lube Oil Pump Stopped (3s)

Both Seal Air Fan Stopped (60s)

Both Control Oil Pump Stopped (3s)

Any sensor in any phase of IDF Motor Winding
Temp. > 130°C

IDF Bearing Vib. Hi-Hi [>7.1 mm/s]

IDF Motor Bearing Vib.(DE) Hi-Hi [>7.1 mm/s]

IDF Motor Bearing Vib.(NDE) Hi-Hi [>7.1 mm/s]

IDF Inlet or Outlet Damper Open FB lost (180s)
Induced Draft Fan (IDF) [Protection Stop]...cntd

IDF Motor Bearing (DE) Temp. > 100°C

IDF Motor Bearing (NDE) Temp. > 100°C

IDF Motor Oil Flow (DE) < 6.1 l/min (120s)

IDF Motor Oil Flow (NDE) < 5.4 l/min (120s)

IDF Radial Bearing (DE) Temp. > 100°C

IDF Thrust Bearing (NDE) Temp. > 100°C

IDF Radial Bearing (NDE) Temp. > 100°C

IDF Stall Probe DP > 500Pa [2oo3] when IDF
Blade Pitch > 38° (120s)

Furnace Draft LL (<600mmWC) [2oo3] (Except 5
min post MFT)
Induced Draft Fan (IDF) [Protection Stop]...cntd

Related FDF Trip when other FDF is OFF or other
IDF is ON

Related FDF stopped with no MFT when other
FDF is OFF or other IDF is ON

Both AH Inlet or Outlet Gas Damper Open FB
lost
Induced Draft Fan (IDF) [Protection Stop]...cntd

Manually trip when IDF Sealing Air Pressure
Diffuser < 250Pa (240min)

Manually trip when Control Oil Pr. < 700kPa
(1200s)

Manually trip when Control Oil Temp. in Tank >
55°C (3600s)

Manually trip when Control Oil Temp. in Tank >
60°C

Manually trip when any Bearing (fan) Temp. >
85°C[2oo3] with Lube Oil Flow Abnormal [<17.5
l/min]
Forced Draft Fan (FDF) Logic
Forced Draft Fan (FDF) [Start Permissive]

Any Induced Draft Fan ON

FDF Outlet Damper Close

FDF Blade Angle Min. Position

Control Oil Pressure > 700kPa

Any Control Oil Pump ON

Any Lube Oil Pump ON

Any CCCWP ON

FDF Radial Bearing (DE) Temp. < 85°C

FDF Thrust Bearing (NDE) Temp. < 85°C

FDF Radial Bearing (NDE) Temp. < 85°C
Forced Draft Fan (FDF) [Start Permissive]...cntd

Lube Oil Temp. in Tank between 15°C & 50°C

Control Oil Temp. in Tank between 15°C & 50°C

FDF Lube Oil Flow Normal [>10.5 l/min]

ESP Inlet & Outlet Dampers Open
Forced Draft Fan (FDF) [Start Permissive]...cntd
Below conditions are also required to start Air &
Gas Draft Group in Auto

Both Air Heaters ON

Scanner Air Fan ON (To start 2nd FDF)

Both IDF ON (To start 2nd FDF)

Total Air Flow > 15% (To start 2nd FDF)
Forced Draft Fan (FDF) [Protection Stop]

Both Lube Oil Pump Stopped (3s)

Both Control Oil Pump Stopped (3s)

Any sensor in any phase of FDF Motor Winding
Temp. > 130°C

FDF Bearing Vib. Hi-Hi [>7.1 mm/s]

FDF Motor Bearing Vib.(DE) Hi-Hi [>7.1 mm/s]

FDF Motor Bearing Vib.(NDE) Hi-Hi [>7.1 mm/s]

FDF Outlet or related AH Outlet 2ry Air Damper
Open FB lost (180s)

Furnace Draft HH (>600mmWC) (Except 5 min
post MFT)
Forced Draft Fan (FDF) [Protection Stop]...cntd

FDF Motor Bearing (DE) Temp. > 105°C

FDF Motor Bearing (NDE) Temp. > 105°C

FDF Radial Bearing (DE) Temp. > 100°C

FDF Thrust Bearing (NDE) Temp. > 100°C

FDF Radial Bearing (NDE) Temp. > 100°C

FDF Stall Probe DP > 500Pa [2oo3] when IDF
Blade Pitch > 39° (120s)
Forced Draft Fan (FDF) [Protection Stop]...cntd

Related IDF trip when other IDF is OFF or other
FDF is ON

Related IDF stopped when other IDF is OFF or
other FDF is ON

Related PAF trip after MFT Reset and Boiler
Light-Off

Related PAF stopped after MFT Reset and Boiler
Light-Off

AH is OFF (5s) or AH is OFF with AH Speed LL
Forced Draft Fan (FDF) [Protection Stop]...cntd

Manually Trip when Control Oil Pr. < 700kPa
(1200s)

Manually Trip when Control Oil Temp. in Tank >
55°C (3600s)

Manually Trip when Control Oil Temp. in Tank >
60°C

Manually trip when any Bearing (fan) Temp. >
85°C[2oo3] with Lube Oil Flow Abnormal [<10.5
l/min]
Primary Air Fan (PAF) Logic
Primary Air Fan (PAF) [Start Permissive]

MFT Reset

Related FDF ON

PAF Outlet Damper Close

PAF Blade Angle Min. Position

Control Oil Pressure > 700kPa

Any Control Oil Pump ON

Any Lube Oil Pump ON

Any CCCWP ON

PAF Radial Bearing (DE) Temp. < 85°C

PAF Thrust Bearing (NDE) Temp. < 85°C

PAF Radial Bearing (NDE) Temp. < 85°C
Primary Air Fan (PAF) [Start Permissive]...cntd

Lube Oil Temp. in Tank between 15°C & 50°C

Control Oil Temp. in Tank between 15°C & 50°C

PAF Lube Oil Flow Normal [>10.5 l/min]

PAF Motor Oil Flow to Bearing (DE) Normal
[>10.8 l/min]

PAF Motor Oil Flow to Bearing (NDE) Normal
[>9.5 l/min]
Primary Air Fan (PAF) [Start Permissive]...cntd

Below conditions are also required if we want
to start Primary Air Group through APS.

ESP Inlet & Outlet Dampers Open

Both Air Heaters ON

Both FDF ON

Both IDF ON

FD Cooling Air Fan ON
Primary Air Fan (PAF) [Protection Stop]

Both Lube Oil Pump Stopped (3s)

Both Control Oil Pump Stopped (3s)

Any sensor in any phase of PAF Motor Winding
Temp. > 130°C [6oo1]

PAF Bearing Vib. (DE) Hi-Hi [>7.1 mm/s]

PAF Bearing Vib. (NDE) Hi-Hi [>7.1 mm/s]

PAF Motor Bearing Vib.(DE) Hi-Hi [>7.1 mm/s]

PAF Motor Bearing Vib.(NDE) Hi-Hi [>7.1 mm/s]

PAF Outlet Damper Open FB lost (3s)

Related FDF trip

MFT
Primary Air Fan (PAF) [Protection Stop]...cntd

PAF Motor Bearing (DE) Temp. > 100°C

PAF Motor Bearing (NDE) Temp. > 100°C

PAF Motor Oil Flow (DE) < 9.6 l/min (120s)

PAF Motor Oil Flow (NDE) < 8.6 l/min (120s)

PAF Radial Bearing (DE) Temp. > 100°C[2oo3]

PAF Thrust Bearing (NDE) Temp. > 100°C [2oo3]

PAF Radial Bearing (NDE) Temp. > 100°C [2oo3]

PAF Stall Probe DP > 500Pa [2oo3] when PAF
Blade Pitch > 37° (120s)
MFT Reset

Furnace Purge Completed (5 min. purge cycle)

ECO Inlet Feed Water Flow Normal

[Minimum Flow is 25% TMCR]

LDO or HFO Leak Test Completed

BPS Configuration
BPS – MFT Circuit
BPS – MFT Circuit
BPS – MFT Circuit
BPS – MFT Circuit
BPS – MFT Circuit
BPS - MFT

MFT PB On

All BFP Stop

Feed Water Flow Low-Low (352 t/h) (30s)
[<70% of Minimum Flow. Minimum Flow is 25% TMCR]
[At 100% TMCR load, feed water flow is 2010 t/h]

All Flame Loss

[When at least one coal feeder is in service AND flame detector power is normal then if:
Either furnace A flame loss OR furnace B flame loss:
Furnace A flame loss is considered as follows: Flame loss on all of 6 elevations:
One elevation example:
{[(Coal feeder on f/b lost OR flame on f/b lost from 3 out of 4 corners on the same elevation)
AND (2 out of 4 corners on adjacent oil elevation: flame on f/b lost OR burner valve open f/b lost)] OR
Respective Coal feeder stopped/tripped}
BPS - MFT

Unstable Combustion
[When all coal pulverisers stopped AND at least LDO/HFO is being burned (Only Oil firing) then if:
(a) [(Atomizing air pressure low (2.5 kg/cm2(g)) OR LDO header pressure low (4.5 kg/cm2(g))
when LDO is being burned) OR All LDO burner valves closed] AND
(b) [(Atomizing steam pressure low (2.5 kg/cm2(g))OR HFO header pressure low (5.5 kg/cm2(g))
when HFO is being burned) OR All HFO burner valves closed]

Reheater Protection
[(When MSV/GV Closed & HPTB closed OR RSV/ICV & LPTB closed) with (30% BMCR OR at least one coal
feeder in service) (10s)
OR (When MSV/GV Closed & HPTB closed OR RSV/ICV & LPTB closed) with 20% BMCR] (20s)
[At 100% BMCR, main steam flow is 2151 t/h]

All Fuel Loss

Both FDF Stop

Both IDF Stop
BPS - MFT

Air Flow Low-Low (25.2% BMCR)

[At 100% BMCR , air flow is 2255 t/h]

DCS Failure

BMS Failure [BMS1 OR BMS2]

Interlock Power Failure [24VDC OR 220VDC]

WSDT Level High-High (14.4m) (30s)
[Added as per ASME TDP-1]
BPS - MFT

Furnace Pressure High-High (400 mmAq) (3s)

Furnace Pressure Low-Low (-400 mmAq) (3s)
BPS - MFT

Water Wall Outlet Fluid

Temperature High-High [A OR
B side]
[650 ~ 534 deg. C - as a function of WS outlet pressure]

Primary Super Heater Outlet

Temperature High-High [A OR
B side]
[650 ~ 534 deg. C - as a function of WS outlet pressure]
BPS - MFT

Boiler Outlet Main Steam Pressure High-High (284.3

kg/cm2(g)) (3s)
BPS - MFT

WSDT Level High-High (14.4m) (30s)

[Added as per ASME TDP-1]
BPS - MFT

In L&T-MHI BPS, only SOE is generated for the first

cause of Boiler Trip.
Operational Sequence for Boiler Start-up

Furnace Purge Start

LDO Leak Test

Furnace Purge Complete

MFT Reset

LDO Shut-Off Valve Open (BPS)

PA Fan Groups Start through APS (DCS)

AB Elevation (LDO) Burner Light-Off

HFO Leak Test

HFO Shut-Off Valve Open (BPS)

CD Elevation (HFO) Burner Light-Off
Furnace Purge

Pulverizer clearing – confirmed

MFT On

Any FDF AND related AH On

Any One IDF On

Both PAF Off

LDO Leak Check Valve Closed OR Charging

HFO Leak Check Valve Closed OR Charging

LDO Shut-Off Valve Closed

HFO Shut-Off Valve Closed
Furnace Purge

All Wind box Dampers Normal

[All Fuel Oil, All Coal, AA & Aux.-2: Not Closed, 2ry Pass Gas Damper Purge Condition: Open 10% Wind
box Damper Purge Condition: Open 10%]

All Fuel Oil Burner Valves Closed

All Coal Feeder Stop

All Igniter Spark Rod Retracted

All Flame Off

Air Flow > 30% BMCR

All Flame Module Normal
Furnace Purge

LDO Leak Test Not Abnormal

HFO Leak Test Not Abnormal

No MFT Condition
LDO/HFO Leak Check

LDO Leak Check:

LDO Leak test is performed to check leakage of burner valves and LDO
fuel piping before burning LDO. Leak test cycle is automatically started
in conjunction with furnace purge start. LDO leak test cycle involves the
opening of LDO leak check valve for a preset time of 60 second to
charge the LDO header with the LDO and then checks whether the
normal pressure of the LDO header is maintained for 3 minutes or not.

HFO Leak Check:
HFO Leak test is performed to check leakage of burner valves and HFO
fuel piping before burning HFO. HFO Leak test is started after the boiler
is warmed up by initial firing through LDO burner AND once LDO to HFO
fuel change over command is issued. HFO leak test cycle is exactly
similar to LDO Leak Check cycle.
MFT Reset

Furnace Purge Completed (5 min. purge cycle)

ECO Inlet Feed Water Flow Normal

[>70% of Minimum Flow. Minimum Flow is 25% TMCR]

LDO or HFO Leak Test Completed
Sequence Logic for Boiler Start-up

Primary Air Fan:

Primary Air Fan Group starts after MFT Reset & before oil firing.

Pulverizer Discharge Valve:

Pulverizer Discharge Valves will open by MFT Reset OR when Coal
Pulverizer Discharge Purge Valves are closed to allow Primary Air
to flow into furnace for coal pipe purging.

Burner Corner Light-Off Sequence:

Each corner burner starts one after another with 15 sec delay
between each burner in following sequence in a pair: Corner 3, 7
-> 1, 5 -> 2, 6 -> 4, 8.

Burner/Ignitor Operation Sequence:

Burner Corner: 3 -> 7 -> 1 -> 5 then Ignitor Off 3 -> 7 -> 1 -> 5

Burner Corner: 2 -> 6 -> 4 -> 8 then Ignitor Off: 2 -> 6 -> 4 -> 8
Boiler Loading Sequence

Burner Abnormal:

In case of any of the following conditions, burner is
declared as abnormal.

Burner Individual Trip Command

Burner Flame Loss

Burner Position Abnormal

Burner Gun Insert Abnormal

Burner Purge Abnormal

Burner Shut-down Abnormal

Burner Ignitor Abnormal
Burner Firing Sequence

Minimum Burners for Startup:

If 6 LDO burners in a pre-defined sequence (3, 7 -> 1, 5 -> 2, 6 ->

4, 8) can’t be started during Boiler Initial Firing, Boiler can’t
operate further i.e. Boiler Light-Off & Loading is halted there.

Initial Firing Completion:

At least 6 out of 8 LDO burners shall be in service for Initial Firing
completion.
Oil Firing Sequence

LDO to HFO Fuel Change-Over:

At least 3 out of 8 LDO burners has to be proved
(burner valve open) for changeover to HFO.

Firing Sequence:
[LDO (AB-3,7,1,5)] -> [LDO (AB) + HFO (CD-3,7,1,5)] ->
[LDO (AB-2,6,4,8) + HFO (CD-3,7,1,5)] -> [HFO (CD)] -
> [Synchronization & Load 10%] -> [HFO (CD+EF)] ->

Unit is synchronized with HFO firing, 1st coal Mill will come
in to service after 20% Load demand is given.
Coal Firing Sequence

[Load 18% & Demand 20%] -> [HFO (CD+EF) & Mill (D)]->
[Load 20% & Demand 35%] -> [HFO (CD+EF) & Mill (D+E)] ->
[HFO (CD) & Mill (D+E)] -> [Mill (D+E)] -> [Load 35% &
Demand 45%] -> [Mill (D+E+C)] -> [Load 50% & Demand 70%]
-> [Mill (D+E+C+B)] -> [Load 75% & Demand 99%] -> [Mill
(D+E+C+B+F)]

2nd Mill will come into service when 35% Load demand is
given.

After second Mill comes in service, Coal Master becomes

AUTO and HFO is taken Out of service automatically
Secondary Pass Bypass Valve

This valves starts opening (0% ~ 50%) in proportion to load

index (70% ~ 100% load) after boiler load reaches 70%
(above sub-critical range) to allow some portion of steam to
pass directly to water separator to reduce pressure drop
through 2RY pass stream.
MRS VFD Bypass

• If Mill Rotary Separator is out of service due to VFD failure then Mill
Motor will continue to run .
• Mill output fineness will be reduced and the extent of fineness reduction
is unpredictable.

• This will increase circulating coal inside the mill that shall cause
vibration, overload and roller slip in addition to other disturbances in
boiler due to expected increase in output fineness of coal even though
mill motor operates at reduced load to avoid chocking. The resulting
vibration may damage the mill mechanically.

58
MRS VFD Bypass

• If we use MRS VFD bypass feature & when separator working at full
speed, the increase in speed of MRS will increase the fineness of coal
and decreases the output of mill. In case of VFD bypass arrangement
when MRS will run at rated speed result into reduction in the mill output
which will increase coal accumulation on the mill table top. As a result
mill tends to be overloaded, increases the vibration of the mill and may
cause damage to the mill equipment in addition to boiler load
reduction. Also the accumulation of coal on the mill table top may
reflect in to combustion of coal inside the mill and damage the mill.
 MRS VFD Bypass
• Mill motor can be run at reduced load with reduction in coal flow to the
mill. But the extent of reduction of coal feeder speed is dependent on
the decision taken by the operator. The subject coal feeder shall have
to be taken in Manual mode of operation from the automatic fuel flow
control (Close loop). Under such circumstances the auto water fuel
control gets disturbed and subsequent disturbances occur in other
control loops of boiler and this tends to disturb all the boiler
parameters. Also the fireball location gets disturbed and the combustion
pattern inside the furnace gets destabilized.
• Hence MRS VFD bypass arrangement should not be used in case of VFD
failure, not to run mill since the coal fineness of mill output will be
unpredictable which may create instability in boiler operation & disturb
boiler parameters and as a result fireball location gets disturbed and
also may result in a boiler tube puncture in long operation. Due to
increment in fineness of coal, stoichiometric ratio may change which
will reflect in to moving of unburnt coal to second pass and may reflect
in to secondary combustion and also will worse opacity of chimney.
Plant Start Up

62
Plant Start Up

63
Plant Start Up

64
Boiler - Turbine Clean-up Flow
Control Concept of Boiler
• Boiler Operation Mode
100
Wet Operation Dry Operation
• Operating BCP • BCP is Out of Service
75 • Once-Through Operation from Eco to SH
Feed Water Flow (%)

• Same Condition
as Drum Boiler

Minimum Flow due

50 to the Furnace
Protection

25%
25
20% 30% 35% 50% 70%
▼ ▼ ▼ ▼ ▼
No.1 Mill No.2 No.3 No.4 No.5 Mill
0
0 25 50 75 100
Load (%)
Start up Control of Boiler
• Wet Operation (1/3)
HPTB
SH3
HPT IPT G

SC2 SH2 RH1

From BFP
SC1 SH1 intermediate stage
RH2 RSC
Partially LPT

Evaporated
WS WS LPTB

WS Separate
D COND
T
WDC
Furnace M
CEP
BCP
Drain is flown into ECO
BR Condensate
ECO inlet or Condenser. Polisher

BFP BFBP
HP LP
DEA
HTR HTR
Start up Control of Boiler
• Wet Operation (2/3)
Steam Flow
Water Flow
through
SH3

Feed Water Flow (%)

Furnace
SC2 SH2 Steam
Flow Recirculation
SC1 SH1 Flow

W W
S S
25% Flow WET
W
S
D Load (%)
WDC
T
Furnace

Recir.
BCP 25% Minimum
Flow Flow for
BR
ECO Furnace
BFP Protection
HP
HTR
Start up Control of Boiler
• Wet Operation (3/3) WDC A /B

Valve Position (%)

SH3

SC2 SH2

SC1 SH1

W W α γ γ’ γ”
S S
WSDT Level
W
S
D LT FX
WDC
γ”
Furnace
T W B
γ’ A
BCP START S WDC
BR
γ
BR
ECO
PI △ FX D
FT
BFP T
HP α
HTR
Start up Control of Boiler
• Dry Operation (1/2)

SH3

Feed Water Flow (%)

SC2 SH2

SC1 SH1

W W
S S
DRY
W
S
D Load (%)
WDC
T
Furnace
Furnace
BCP

ECO
BR
Evaporated Feed Water Flow
BFP
= Steam Flow
HP
HTR
Start up Control of Boiler WDC A/B

Valve Position (%)

• Dry Operation (2/2)

SH3

SC2 SH2

SC1 SH1

W W α γ γ γ
S S ’ ”
WSDT Level
W No Level
S
D LT
γ”
WDC
Furnace
T W B
γ’ A
BCP S WDC
γ
Stop BR
BR D
ECO
FT
Close T
BFP
HP α
HTR No Level
Start up Control of Boiler
• Wet/Dry Change Over

BID > 30%

S DRY Mode
R
BCP Start
WET Mode
BR Valve
Full Close
MFT Change-over timing
Synchronized depends on BCP
start/stop
BID < 22%

WET Change Over Area DRY

22% 30% BID(%)
Water Separator Control WSDT

Boiler Recirculation Flow WSDT Level Injection Water Flow

FT LT
FT

Calculate
√
√ Supercritical
Condition Required
0% T
Injection Water
Flow
△ FX
Load Demand △

FX 2 FX 3 △ FX PI
PI

Rate Rate PI

Injection water
BR valve control WDC-A control WDC-B control BCP Warming
demand Discharge flow control
demand demand
control demand demand
[operation in Wet [operation in [operation in Wet
[operation in Wet
mode] Wet mode] mode & Dry mode [operation in
(emergency)] Dry mode] mode]
 Wet To Dry Transition Control

To ensure the transition occurs in one direction only, the steam

temperature is controlled via the manipulation of the firing rate to feed
water ratio (FR/FW). In once-through operation, WFR controls the water
separator outlet temperature.

WFR (FR/FW) is increased by increasing the firing rate. The higher

FR/FW ratio will cause the furnace wall exit quality to increase above
100%. Simultaneously, desuperheater spray-water flow will increase to
maintain main steam temperature which will contribute to increasing
the furnace wall quality.

During low load (below 22% Load), drain is collected in the WSDT and
BCP is used to re- circulate this drain. This is the WET mode of
operation.
 Wet to Dry Transition Control

During Wet mode of operation WSDT level is controlled using BR valve
and WDC valves.

During DRY mode, WSDT level is maintained using BCP warming return
flow control valve.

During start-up as the firing rate & load increases ,the pressure in the
separator also increases. The separator outlet pressure is converted to
temperature at saturation conditions via a steam table function
generator programmed into the control system.

The derived temperature becomes the set point for control, while the
actual separator outlet temperature is the process variable.

Separator tank level is continuously monitored and compared to a level

set point that varies in relation to load.
Wet To Dry Transition Control

At higher loads (above 30% Load), Superheated steam enters

the WS and so no drain is collected in the WS and BCP is
stopped. This is the DRY Mode of operation.

Based on the BCP operation (STOP) and Degree of superheat

at the inlet of WS (> 5°C), the operation mode is judged to
have changed from WET to DRY between 22% to 30% of load.

During DRY mode, WSDT level is maintained using BCP

warming return flow control valve.
 Control Concept of Boiler • Chart of Wet / Dry Mode
Startup Shutdown

WET DRY WET

TB Valve
Position

20% 30% 100% 30% 20% MW

Steam Press
Control
TB Valve WFR BID WFR

TB Valve
Steam Press Close on Back up Press mode
Control
WFR
Not used Steam Steam Press
Degree of Superheat Control
Press Control
or Steam Temp. Control
Control
Key Control Signals

BID is the basis for generating Feed water flow demand and Fuel Flow
demand

MWD is the basis of generating Turbine Master demand

BIR is some bias added to the demands of various closed loop to

improve boiler response during transient conditions

BID = MWD + ∆P + ∆MW (i.e. BID varies to compensate for any pressure
error and MW error)
Key Control Signals

Load Target can be given by the Operator when Unit is in CC mode
(Station mode) from Load setter Loop Plate or from Load dispatch
centre in case of CC – Dispatch mode

Load INC/DEC Rate can be generated in

AUTO : Load rate is generated as function of MWD, depending on

the unit start up mode(cold/warm/hot/very hot/normal)

Manual: From Load rate Loop plate

In case Load increase or decrease is blocked or Load is on HOLD,

the Rate becomes Zero. i.e the Load is held.
Control Concept of Boiler Boiler / Turbine
• Once-Through Boiler (DRY Mode) Special Coordination
Main Steam Press control Control Mode (DRY)
MW Target Boiler Master Main Steam Temp Eco outlet O2
Control
Unit
Master Rate FX △ Steam Temp /
Control Superheat Control O2 Control
PI
Water Fuel Ratio Firing Rate
MW Demand
Demand (FRD)
Σ FX Σ FX ×

Boiler Input FX Air Flow

MW △ Demand (BID) Demand

Turbine Feedwater Fuel Air Flow

Master PI 10 ∆
Control Control Control
Control
PI

Spray
Governor Fuel flow control valve FDF
BFP Control
TB valve Coal feeder
FW control valve Valve
Fuel Flow and Air Flow Signal
Input (X) FUEL FLOW DEMAND
Output(Y) AIR FLOW DEMAND 2500

X Y 2000
UNIT t/h t/h
1 0 0
1500
2 143 877
3 203 1214
4 263 1460 1000
5 293 1630
6 323 1772 500
7 345 1920
8 350 1920
0
9 0 100 200 300 400
10
Air Flow Control INS

Instruments used

Eco. Outlet O2 analyzer

FDF A / B Inlet Air Temp. Element

FDF A / B Air Flow

FDF A / B Stall warning Differential Pressure Transmitters (UPsk)

FDF A / B Stall warning Pressure transmitters (P1) C

FDF A / B Stall warning Temperature elements (t1)

FDF A / B Stall warning Differential Pressure Transmitters (UPs)

Control Drives

A FDF A / B blade pitch control drive

Fail safe condition: Hydraulic Oil fail & 240 VAC UPS failure to Lock.
 AFR1
Air Flow Control
AFR 2

The set point is based on Air Flow demand (AFD) calculated as a

function of firing rate demand (FRD) and Boiler Input rate (BIR-Air) and
corrected to ensure complete combustion by monitoring for flue gas
oxygen and multiplying the demand with Air Fuel Ratio (AFR).

FDF bias station is provided to compensate load imbalance between FDF

(A) and FDF (B)

The operator can vary O2 set value using bias loop plate. O2
measurement signals have large ripples, therefore, a function generator
is provided to give some dead band on the deviation.
 Air Flow Control

Process gain correction as per the number of Auto FDF is provided.

The AFR control is on standby mode for automatic operation, when the
firing rate demand (FRD) is at 30% MCR or < air flow demand is for a
minimum air flow rate (The air fuel ratio signal is 1.0.) or any FDF is
stopped

The AFD is cross-limited with total fuel flow to prevent fuel rich
condition in the furnace. FDF blade pitch is controlled by a controller
that receives an error signal from the comparison of an air flow demand
and an actual total measured air flow which can be determined by
adding the primary air flow for each coal mill and the secondary air flow
from FDF.
Air Flow Control

FDF blade pitch demands are forced to maximum (100%) open while
both FDF are stopped so that natural ventilation of the furnace could be
done

Stopped FDF blade pitch demand is forced to minimum (0%) open if the
other fan is running, to prevent reverse flow of the air through the
stopped fan

The FDF blade demand is fed through a direction block interlock which
blocks demand change. The direction block interlock prevents the FDF
demand increase when the surging block function detects an impending
FDF surging condition
Furnace Draft Control
Instruments used

Furnace flue gas draft PT

IDF Stall warning PT (P1)

IDF Stall warning DPT (UPsk)

IDF Stall warning DPT (UPs)

IDF suction inlet Temperature Element (t1)

Control Drives

IDF blade pitch control drive

Fail safe condition : Hydraulic Oil Fail, Lock.

Furnace Draft Control

The set point value is constant [-10mm WC (g)] and operator has option to
vary the furnace draft set value using set value bias loop plate.

Furnace pressure signals have large ripples, and therefore, time lag on the
measured signal and a function generator to give some dead band on the
deviation are provided.

Bias is used to compensate load imbalance between IDF (A) and IDF (B)

Process gain correction as per the number of Auto IDF is provided.

he PI controller is blocked during the INC and DEC operation depending
upon the occurrence of FCB.

Correlation between IDF moving blade position and FDF moving blade
position.
 FDC 1
Furnace Draft Control FDC 2

The PAF and FDF blade position is used as the feed forward signal to
improve response during a load change.

Stopped IDF blade pitch demand is forced to minimum (0%) if the other
fan is running to prevent reverse flow of the stopped fan.

The IDF blade demand is fed through a direction block interlock which
blocks demand change during furnace draft extremes or when the
Surge is detected

MFT Condition:
IDF blade demands are forced to minimum position for 2-3 sec for
furnace implosion protection .The limit also depends upon the no of IDF
running.

IDF blade pitch demands are forced to maximum (100%) open while
both IDF are stopped for natural draft.
BID and Furnace Windbox DP Signal

200.0
X Y
MW mmH2O 160.0

0 147.0 120.0

711.3 147.0 80.0

40.0

0.0
0 100 200 300 400 500 600 700 800
 SADC Oil & Coal Damper 1 2 3 4 CAT

Instruments used : Wind box to Furnace Differential PT

Corner-1 Corner-7
BR-1
1st I/P-Burner Damper Damper
A Corner-3 Corner-5
BR-2 Damper Damper

Corner-2 Corner-8
BR-1
2nd I/P-Burner Damper Damper
A Corner-4 Corner-6
BR-2 Damper Damper

Coal dampers A (08) to F (08)

Oil dampers : Individual I/P control for each of the

HFO/LDO Damper AB( 01-08)
8 7 6 5

HFO Damper CD(01-08)

HFO damper EF (01-08) 1 2 3 4
SADC

BMS & BID from DCS control SADC to obtain proper air/fuel ratio for
each burner and in each elevation

Coal & oil dampers for AB elevation is based on the condition of HFO
firing or LDO firing. An automatic switchover condition is available for
selection of the Fuel oil pressure signal based on the type of burner HFO
or LDO in service

The operator has provision to provide bias value from damper bias loop
plate based on the individual coal/oil/Aux damper grouping.
SADC Aux Air Damper Control

Total 8 nos at bottom most elevation , Fail safe condition: Air Fail Open

Corner-1 Corner-2
BR-1
Damper Damper
1st I/P
Corner-7 Corner-8
BR-2 Damper Damper

Corner-3 Corner-4
BR-1
Damper Damper
2nd I/P
Corner-5 Corner-6
BR-2 Damper Damper

8 7 6 5

1 2 3 4
SADC Aux Air Damper Control AAD

It controls the additional air flow into the furnace by AA Damper

Control drive

The position demand is based on BID

Operator has option to vary the damper position demand using bias
loop plate for left and right side respectively. In order to enhance the
controllability during a load change

BIR demand is provided for both left and right to enhance the
controllability
 SADC AA Port Nozzle Angle Control AAN

Individual I/P to each corner ( 1-8) of AA port nozzle

Controls the angle of AA port nozzle (±30⁰) with air fail safe lock

Position demand is based on BID

BIR demand is provided to enhance the controllability during load

change.BIR is the control signal which are changed more than the
corresponding quantity to the load demand

Special logic for correcting temperature difference between the right &
the left is also considered for tuning correction different parameters of
RH Steam, Synchronization, and Gas damper are considered.
 Dampers Conditions Damper operation
Coal dampers MFT and not Hot banking Open
During Hot banking mode (under Close
MFT)
Coal burner in service Program control in proportion to coal flow (Bias function based on the
boiler load or the number of operating pulverizer shall be considered.)

Coal burner out of service and Program control in proportion to oil header pressure to act as aux. air
adjacent oil burner in service damper for oil burner.
Both coal burner and adjacent oil Minimum opening *
burner out of service
Oil Dampers MFT and not Hot banking Open
During Hot banking mode (under Close
MFT)
Oil burner before light off Preset position *
Oil burner in service: Program control in proportion to oil header pressure.
Oil burner out of service Minimum opening*
Adjacent coal burner in service Program control in proportion to either of the following:

Average coal flow of upper and lower coal burner elevations, if
both the elevations are in service

Coal flow of the corresponding coal burner’s elevation, if only one
adjacent elevation is in service
Auxiliary MFT and not Hot banking Open
damper
During Hot banking mode (under Close
MFT)
A- coal burner in service Program control in proportion to coal flow of A- coal burner.
A- coal burner out of service
Boiler load < 30% MCR: Diff. Press. control between furnace and
wind-box.

Boiler load > 30% MCR: Minimum opening*
Wind box Inlet Damper Control WBID
PID

Control Drives are Fail safe Lock on Air fail

o One Wind box Inlet damper for(1, 2 ) corner

o One Wind box Inlet damper for(3, 4 ) corner 8 7 6 5
o One Wind box Inlet damper for(5, 6 ) corner
1 2 3 4
o One Wind box Inlet damper for(7, 8 ) corner

Wind box Inlet Damper Controls the air flow into the burner assemblies

Position demand is based on BID and minimum opening is 30%. MFT

condition is full open & during HOT BANKING all are closed.

O2 balance between the left and right side is done for this damper, i.e.
if difference between the left and right side Eco. Outlet O2 is there then
one set of damper starts closing (Damper 1-2 and 7-8) and other starts
opening (Damper 3-4 and 5-6) or Vice Versa depending upon situation.
Steam & Water Flow Measurement

Steam flow to turbine in subcritical case is derived from turbine 1st

stage pressure,1st stage temperature ,main steam pressure & main
steam temperature as M= P 1st.F.K where K = (MS Temp-1st Stage
Temp)/(MS Pr-1st Stage Pr) and F = K(T 1st/T MS+SQRT(T 1st/T MS)

First Stage pressure measurement is not considered in super critical

plant, the steam flow to turbine is not used for plant control , only used
for monitoring. The PT after GV and before HPT inlet nozzle is used for
this purpose.

BCP warming water flow to 2RY SH is not considered in total spray water
calculation as it is within the feed water circuit.

BCP Injection water flow to 2RY SH is not considered in total spray

water calculation as it is negligible
Boiler Input Rate (BIR)

BIR is applicable only during Transient condition. During stable load, BIR = 0.

BIR is generated to improve boiler response during load changes.

BIR is generated based on following signals:

Load change Width (ex: 50 MW or 200 MW)

Load change Rate (ex: 0.5% TMCR/min or 2.0% TMCR/min)

Load Index(ex: Load change from 50 MW to 100 MW or 550 MW to 600 MW)
Feed Water Control FW

Low load FCV fully closes at MW>35%

There is no DP measurement & control across FCV. (FWD-BFP OL
flow) deviation is dynamically +/- trimmed by ( BFP OLP-BFPHDRP)
deviation

For Economizer steaming protection during runback / sudden load
down +bias is added with FWD signal to increase the FW flow

To ensure min FW flow to the furnace pass +bias is added in wet
mode operation for SH spray flow since the spray line is branched
off from the eco outlet

Rate of change of BID / MWD is added as FF signal to take care of
sudden load demand

BID+BIR is cross limited with total fuel flow to ensure unbalance
never exceed the control limit

-ve bias is added to FWD during BFP service in and +bias is added
to FWD during BFP service out to stabilize the FW flow
BID & FFD Signal

X Y 500.00
UNIT MW t/h

1 0 0.00 400.00

2 198 136.98
300.00
3 264 171.87

4 396 240.77 200.00

5 528 310.19
100.00
6 660 376.55

7 698 392.33 0.00

0 200 400 600 800 1000
8 711.3 399.77
BID vs Feedwater Flow Signal

X Y 2500
UNIT MW t/h
1 0 0 2000
2 198 668
1500
3 264 823
4 396 1180
1000
5 528 1588
6 594 1805 500
7 660 2010
8 698 2111 0
0 200 400 600 800
9 711.3 2151
Total Fuel Flow Signal(X) & Air Flow(Y)

X Y 125
UNIT t/h %
1 0.00 0 100
2 136.98 38.72
75
3 171.87 45.55
4 240.77 64.62 50
5 310.19 77.73
25
6 376.55 94.78
7 392.33 99.99 0
8 399.77 100.00 0.00 100.00 200.00 300.00 400.00
Fuel Flow Control

Unit is always started with LDO firing, after Hot clean up is completed
Fuel is changed over from LDO to HFO.

HFO Master will be control flow, after 4 HFO burners come in service.

HFO Load program will become AUTO, after 6 BNR comes in to service.

Unit is synchronized with HFO firing, 1st coal Mill will come in to service
after 20% Load demand is given.

2nd Mill will come into service when 35% Load demand is given.

After second Mill comes in service, Coal Master becomes AUTO and HFO
is taken Out of service.
 FFD1
Fuel Flow Control HFO1
FFD3

Fuel Flow demand is generated based on BID

Fuel flow control will becomes AUTO, when more than 2 LDO burners
are taken in service

In wet mode FF controls the MS Pressure

WFR is added to the Fuel flow demand. WFR is generated based on the
MS temp error , Superheat Temp Error, Furnace outlet temp error

Fuel flow demand is cross limited with Feed water flow and Air flow

Air flow demand is generated based on the Fuel flow demand

Fuel Flow Control

Fuel flow demand is then converted to LDO flow demand / HFO flow
demand / Coal flow demand based on LDO/HFO or Coal Master is AUTO

LDO Flow CV and HFO flow CV will be modulated to control Pressure till
2 BNR or 4 BNR are in service respectively

Even when LDO or HFO flow CV are modulated to control flow, some
minimum pressure is always maintained

In case of exclusive coal firing, fuel flow demand is divided equally

among the number of Coal feeders operating
Load demand vs 1RY SH Outlet Temperature Set

X Y
500
UNIT MW degC
1 0 355.20
450
2 198 355.20
3 264 363.33
4 396 382.59 400
5 528 416.12
6 594 429.15 350
7 660 433.02
8 698 434.53 300
9 711.3 434.81 0 200 400 600 800 1000
Load vs 2nd ry SH outlet temp

X Y
600.0
UNIT MW degC
1 0 526.1
2 198 526.1 550.0
3 264 536.2
4 396 540.6
5 528 543.0 500.0
6 594 544.1
7 660 544.8
8 698 544.8 450.0
0 200 400 600 800 1000
9 711.3 544.7
Load vs 3ry SH outlet temp set

X Y
600.0
UNIT MW degC
1 0 500.0
2 198 531.0 550.0
3 264 552.0
4 396 569.0
5 528 569.0 500.0
6 594 569.0
7 660 569.0
8 698 569.0 450.0
0 200 400 600 800 1000
9 711.3 569.0
Main Steam Temperature Control

MS Temp set point is a dynamic function of Load Index with Delay

MS Set will track the Actual MS temp till SH Start up mode is ON

Main steam temperature is controlled by WFR and SH Spray

In DRY mode WFR is used to control the MST

WFR is generated based on the Temperature error at MS line,

WS inlet, Furnace outlet.

WFR is added as a bias to Fuel flow demand.

WFR can be positive or negative bias.

 Water / Fuel Ratio Control FFC2

WFR takes care of heat absorption of actual heating value of fuel &
burner elevation in service

The superheat rate signal is generated based on the error between
water separator inlet temperature and the saturated temperature at
water separator outlet pressure.

WFR controls the superheat rate of WS inlet steam at low load and MS
temperature at high load

WFR assist MS temp control by adding steam temp error as FF signal of

each WWOL,1shOL,2rySHOL,3rySHOL

WWOL & 1SHOL temp SP are generated dynamically from LDD

LDD always trim the WFR signal

 MS Temperature Control

Main steam temperature set point is generated on the basis of Load
Index and controlled by WFR & SH spray.

In DRY mode of operation WFR is used to control the MST.

WFR is generated based on the Temperature error at MS line, WS
inlet, Furnace outlet.
WFR is added as a bias to Fuel flow demand.
WFR can be positive or negative bias.

In WET mode main steam temperature is controlled by two stages of SH

spray

1ry SH Spray control valve

2ry Spray Control valve

Main Steam Temperature Control

WFR reduces fuel flow in order to protect boiler tube in case of

following FF signals :

WWOL superheat rate high

Furnace gas temp high

WWOL temp high based on WSTTSAT at WSOP

SH spray is also applied to cover transient state (e.g. during load

change), because its response is faster than water fuel ratio control.

Till Synchronization all SH/RH spray valves are forced Closed. Also in
Case of Steam block or MFT, Valves are forced closed
 MST 1
MS Temperature Control
MST 2

MST set is function of Load Index(Delay)

MS Temp start up mode is ON from MFT till 500 Deg C is reached or

Operation mode changes to DRY. (MST reaches 500°C around 20%Load)

MS Set will track the Actual MS temp till SH Start up mode is ON

After the Start up Mode is RESET, MS Temp SET will be Load based and
increase/decrease with a Rate which is also a function of Load
Index(delay)

MS Temp Bias permit is available only after MS Temp reaches 500 deg C

MST BIR is applicable only after LD(delay) is more than 50% TMCR
Control Outline of 1ry SH Spray Control valve
1ry SH Spray control valve

The valve will mainly control the WS inlet Superheat rate only when
following conditions are available:

If WFR is not able to maintain the SH rate then only Spray is used.

In DRY mode of operation, when the Load is less than 610MW and WS
outlet Press is not more than 200kg/cm2 and TWSI superheat upper or
lower limit is reached

Load based TWSI SH upper and Lower limit is determined dynamically

Whenever DSH outlet Temp nears Tsat, Over injection Controller will
control the spray valve opening to maintain the DSH outlet temperature
15°C above saturation temperature

Also some bias is added to maintain 2ry SH Outlet temp.

Superheat Rate Controller

SH rate Set point based on the WS outlet Pressure
Superheat Rate Controller

TWSI superheat Upper/ Lower limit is “ON”, when the actual SH rate is
more or less than the Load based Superheat rate upper / lower limit

The valve will control the Superheat rate only when following conditions
are available: In DRY mode of operation, when the Load is less than
610MW and WS outlet Press is not more than 200 kg/cm2 and TWSI
superheat upper or lower limit is reached.
Superheat Rate Controller
1ry Spray CV control (Over injection / min openingcontrol)
 MS Temperature Control-2ry Spray Control valve

SH spray is applied in two stages cascade control and controlled separately on A-
side and B-side by each corresponding drive

Fail safe condition: Air Fail Close
• 2ry Spray control valve is used to maintain TFSO. Main steam temp is controlled
using cascade control.
• Primary Controller:
o This controller fine tunes the T3SI Set, based on the MST and DSDT Error.
DSDT deviation is controlled only in DRY mode of operation. DSDT error is
limited within +/- 6 Deg C.
o FF: FF signal is Load based T3SI and BIR signal.
o LL : Tsat + 15°C
o This controller will be normally in operation after MS Start up mode is RESET.
o HL: Normally 600 °C. In case the 2ry Spray CV demand is less than the min
opening required, the HL is held at the existing value. This helps to prevent
the T3SI set from increasing, and thus the Spray valve demand from
decreasing further.
MS Temperature Control-2ry Spray Control valve

Ts:

When the MS Temp start up mode is ON (From MFT till MST reaches
500°C or Operation mode changes to DRY) OR

2ry Spray CV demand is less than the min spray opening and actual MST
is less than MST Set by 10°C or more.

Whenever the Spray valve demand becomes less than its min opening and
the actual temp is less than MST Set by 10°C or more, than Primary
controller will be switched to tracking mode. This is reset wind up circuit.

Tr: Tracked signal will be the Actual T3SI.

MS Temperature Control-2ry Spray Control valve
• Secondary controller :
o This controller generates the 2ry Spray valve Position demand based on the
T3SI Error.
o LL: Load based Min Opening except in case of Over Injection, when it is 0%
o HL:
 Normally 102%.
 In case of Over Injection,
 HL = 0%, if the Margin between actual MST and its SET is more than
10°C ,
 HL =102%, if the during over injection margin between MST and its
SET is less than 10°C.
o Ts: when the 2ry Spray CV is not AUTO
o Tr: 2ry Spray Valve Opening.

• During MST Start up mode, both the controllers are in Tracking mode, and the
2ry Spray control valve will be opened as per the start up Program.
 TILT
RH Temperature Control RHT 1
RHT 2

Main Control is by Gas Distribution Damper & backup control by burner

nozzle angle

To increase the RH outlet temperature, RH side Dampers are opened more,

to allow more flue gas to pass through RH side. SH side dampers are
operated proportionally

RH steam temp set point is generated based on the Load demand.

BID gives compensation bias during run back condition

There is provision to adjust the Tilt to rectify the RH outlet A and B

imbalance

An over injection protection is provided to control steam saturation point
 RH steam temperature Control Coal Burner-F
Upper Burner Oil Burner-EF
8 7 6 5 Power cylinder
Coal Burner-E
1 2 3 4
Coal Burner-D
Corner-1 Middle Burner Oil Burner-CD
I/P + BR Power cylinder
Coal Burner-C

Coal Burner-B
Lower Burner Oil Burner-AB
Power cylinder
Coal Burner-A

Variation of Burner nozzle angle control the flue gas temperature by

varying the flame length, controlling the Reheat Steam Temperature.

Default position is (50% ,0 degree) & Variation is +/- 15 degree

RH Steam Temperature Control

Emergency Control

Burner tilt is based on Load index. It is adjusted to Tilt & rectify the RH
outlet A and B imbalance

RH spray control is used for transient temperature variations during

load change

When Gas distribution damper control have reached its lower limit
(20°)

During Load up & Burner nozzle angle control are ineffective or have
delayed response
Sliding Pressure Operation
Gen MS Pr
300.00
X Y
UNIT MW kg/cm2(g) 250.00
1 0 90.80
200.00
2 198 91.88
3 264 113.90 150.00
4 396 159.69 100.00
5 528 216.69
6 594 245.96 50.00
7 660 245.96 0.00
8 698 245.96 0 200 400 600 800 1000
9 711.3 245.96

Main Steam Pressure (MSP) of Modified Sliding pressure curve is higher than
Main Steam Pressure of Pure Sliding pressure curve.

Turbine control valve will automatically open/close as per set main steam
pressure
Sliding Pressure Operation

By the sliding pressure in proportion to the generator output, steam
quantity at turbine inlet can be changed at a constant volume flow
while keeping governing valve full open.

A smaller governing valve loss enables

improvement of HP turbine internal efficiency

Decrease of feed water pump throughput

Boiler reheat steam temperature can be maintained at higher level
because of higher temperature in HP turbine exhaust steam

In comparison to constant pressure operations, a sliding type enables

much improvement in plant efficiency under partial load operations.

Improvement of relative Turbine Heat Rate due to Sliding Pressure

Operation
Specific Interlock to Sliding Pressure boiler

Sliding pressure operation is intended for static determination of the

unit and not intended to make load changes

Based on the sliding pressure curve, the set value of the MS pressure
changes also and the large deviation causes large / small demand to
FW,FF,AF compared to static characteristics which lead to overshoot /
undershoot in MW generation, MS & RH steam temperature.

This is because opening of governing valve opening is almost full open

and constant during sliding pressure operation with constant volume
flow and MW control occurs by changing the MS pressure

Hence the MS pressure setting at the current static state is on Hold to

stand by mode under this condition
MS Pressure Control by HPBP

MSP set comes to auto if unit is synchronized & boiler is in wet / dry
mode with a deviation between MSP program set & manual set
< + /- 0.3 MPa

MSP demand is generated based on MWD if unit is in CC/BF mode

MSP demand is generated based on BID if unit is in other mode

The HPBP Pressure set point is calculated by the sum of the MSP demand
and the specified bias.
MS Pressure Control by HPBP

After the load demand goes above the regulated load, the set point bias
is in effect. As a result of this, the HP TB control valves are normally
closed and operated as back up control to prevent the Main Steam
Pressure from rising excessively

Override function of the HP turbine bypass valve outlet temperature is

also provided. If the HP turbine bypass valve outlet temperature
exceeds the preset value, the control output is blocked by the maximum
limit function

When condenser vacuum pressure is low or HPTB valve outlet

temperature high occurs, then HPTB control valve will be forced to
close.
MS Pressure Control by HPBP HPBP

When Fast cutback is in operation, the HPTB valve will be forced to fully
open.

HPTB Spray water control valve set point is generally constant

The position demand of HPTB valve is used as a feed forward signal for
HPTB spray water Control valve to improve response.

When condenser vacuum pressure is low or HPTB pressure control valve

is close or all BPF are STOP, then spray valve will be forced to close.
MS Pressure Control in Boiler Follow and Turbine
Follow Mode

Boiler follow mode:

Boiler Master Auto(AF,FF,FD,FW) & Turbine Master Manual ->
The main steam pressure is controlled by the fuel supply,ie.
boiler and the MW is controlled by the turbine Governor valves.
The response to grid frequency variation is fast. The system
eventually breaks into oscillation.

Turbine follow mode:

Boiler Master Manual & Turbine Master Auto ->
The main steam pressure is controlled by the turbine governor
valves and the MW is controlled by the fuel supply,ie Boiler. The
response to grid frequency variation is sluggish & equal to the
time constant of the boiler ( approx 2 min max).Very stable
control.
Unit Coordinated Control

The MWD is given both to the boiler & TG so that energy i/p to the
boiler matches to the energy o/p from the TG

The CC scheme is responsible for driving the BTG set as a single

entity, harmonising the slow response of the boiler with the faster
response of the turbine-generator, to achieve fast and stable unit
response during load tracking manoeuvres and load disturbances.

In CC strategy a higher rate of load change is ensured without

violating thermal constraints. The process is characterized by
high nonlinearity and uncertainty.

All the main control loops must respond to a central command

structure ( MW & FreQ by TG, and MSPr,MSTmp,FW,FF,AF by
Boiler input)
Unit Coordinated Control

Boiler Master & Turbine Master Auto -> It is compromise between
BFM & TFM.

BFM utilizes the turbine governor valve as fast-acting load

controller, since quick opening the governor valves leads the quick
increase in load and releasing the stored energy in the boiler meets
short-term increases in MW

BFM ensure grid frequency support but the large deviation in the
steam flow rate & pressure occurred due to this is used to
regulate the boiler input ( FWF,FFD,AFD) to stabilize the MS
pressure
 Unit Coordinated Control

Unit coordinate control generates three main Demand signals –
BID – Boiler Input Demand
MWD – Turbine Master
BIR – Boiler Input rate

BID = MWD + ∆P + ∆MW (i.e. BID varies to compensate for any pressure
error and MW error)

Boiler input demand is the basis for generating Feed water flow demand and
Fuel Flow demand.

MWD is the basis of generating Turbine Master

Boiler input rate is some bias added to the demands of various closed loop
to improve boiler response during transient conditions.
UCC in Sub Critical Plant

MS Pressure control is done in TCS by Limit pressure mode & Initial

pressure mode

Initial pressure mode comes when runback action comes into picture or
it is selected from console.

A Pressure deviation signal (difference of required pressure as per load

and actual pressure) is fed to the controller

If deviation is more than set value (Actual > required) the pressure
controller output remains as maximum saturation.

If deviation fall less than the set value the output of the pressure
controller jumps from saturation to minimum output
UCC in Sub Critical Plant

Limit pressure is used when turbine is in load control mode

This mode is used once the load on turbine is stabilized

A biasing of 10Kg/Cm2 is given in this loop from Initial pressure mode

All the action start after the pressure drops by more than 10Kg/Cm2

A small pressure correction signal is applied +/- side to load set point
control

Boiler following or “constant pressure” mode is the most commonly
used mode in power plant coordinated control and MS Pressure is
maintained by fuel flow control
Control Mode selection of Super Critical Plant
Boiler control mode Control condition Remark

Coordinate CC mode ･Gen. Synchronized Normal operating mode

Control (Dry) ･Turbine master control : auto ------------------------- MW control (MW target is set by MW target is set by
mode operator or dispatch (CENACE)) operator or
･Boiler input control : auto (as follows) –------------- follow to MWD and Pt control dispatch
Feed water flow control/ Fuel flow control/ Air flow control/ Furnace draft control : (CENACE)
auto
･Water fuel ratio (WFR) control : auto --------------- Superheat rate of Twsi control
*BID = MWD + Pt control correction (MWD ～ MW target and load rate set)
CC mode ･Gen. Synchronized Normal operating mode
(Wet) ･Turbine master control : auto ------------------------- MW control (MW target is set by MW target is set by
operator) operator
･Boiler input control : auto (as follows) -------------- follow to MWD
Feed water flow control/ Fuel flow control/ Air flow control/ Furnace draft control :
auto
･Water fuel ratio (WFR) control : auto or HP-TB valve main steam press control : auto ---
------ Pt control
*BID = MWD (MWD ～ MW target and load rate set)
Boiler BF mode ･Gen. Synchronized Turbine master manual
Follow (Dry) ･Turbine master control : manual operation
mode ･Boiler input control : auto (as follows) -------------- follow to MW and Pt control Boiler input follow to
Feed water flow control/ Fuel flow control/ Air flow control/ Furnace draft control : MW + Pt control
auto
*MWD = MW (MW tracking)
*BID = MW (rate limited) + Pt control correction
BF mode ･Gen. Synchronized Turbine master manual
(Wet) ･Turbine master control : manual operation
･Boiler input control : auto (as follows) -------------- follow to MW Boiler input follow to
Feed water flow control/ Fuel flow control/ Air flow control/ Furnace draft control : MW
auto WFR or HP-TB –-- Pt
･Water fuel ratio (WFR) control : auto or HP-TB valve main steam press control : auto --- control
------ Pt control
*MWD = MW (MW tracking) *BID = MW (rate limited)
Control Mode Selection of Super Critical Plant
Boiler control mode Control condition Remark

Boiler BI mode ･Gen. Synchronized Boiler input is set

Input (Dry) ･not CC or BF mode directly by operator
mode ･Feed water flow control : auto TM : auto ----- Turbine
*MWD = MW (MW tracking) follow mode
*BID ～ BI target and load rate set (BI target is set by operator) (Pt control)
** In case of Runback, BI target is set to preset runback target load. TM : manual ----- Pt
control is manual
BI mode ･Gen. Synchronized Boiler input is set
(Wet) ･not CC or BF mode directly by operator
･Fuel flow control : auto TM : auto ----- Turbine
*MWD = MW (MW tracking) follow mode
*BID ～ BI target and load rate set (BI target is set by operator) (Pt control)
TM : manual ----- Pt
control is manual
Boiler BM mode ･Feed water flow control : manual TM : auto ----- Turbine
manual (Dry) *MWD = MW (MW tracking) follow mode
mode *BID = Fx (Feed water flow) or MW (in case of Feed water flow signal (Pt control)
fault) TM : manual ----- Pt
Fx : Feed water flow is converted to Load index signal according to control is manual
static character.
BM mode ･not Gen. Synchronized TM : auto ----- Turbine
(Wet) or follow mode
･Fuel flow control : manual (Pt control)
*MWD = MW (MW tracking) TM : manual ----- Pt
*BID = MW (rate limited) control is manual
Load INC/DEC Block conditions
UCC

Load INC block

permit is available
only in case of CC
or BI mode
when no FCB or
Runback exists
Load INC/DEC Block conditions

Load DEC block

permit is
available
Only in case of
CC or BI mode
when no FCB or
Runback exists
 Start up for UCC

During start up & before synchronization , Turbine master ( governor) is
separated from UCC and if FW & FF is on Auto, BFM is selected

After synchronization during constant pressure operation in wet zone MS

pressure is controlled by HPBP & WFR

In BFM, Operator increase/decrease the unit loading manually in Turbine

master manual control & the BID to the boiler is automatically set to
control the main steam pressure which is corrected on actual MW signal

MS pressure set point demand to boiler is set by MWD as per sliding pr

curve in BFM / CC mode or by BID in other mode

In BFM & Sliding pressure operating zone, pressure set point shall be
Hold. The reason is shown in the next slide
MS Pressure SP Hold in BFM & Sliding Pressure Zone
UCC start up BMM(w)=>BFM(w)=>CC(w)=>CC(D)

When the turbine master is set to AUTO with turbine valve transfer
completed just before synchronization, the BFM can be changed to BI
mode /TFM ( Turbine Master Auto , Boiler master Manual) by operator
PB

Operator can select BI mode or CC mode from Loop plate whenever the
permissive are available.

In BI mode the MW is set by the operator manually under the condition
of boiler input control manual and Turbine Master Auto.

The MW demand to the turbine governor is automatically set to control

the main steam pressure.
Now there is need to change the manual set point to match the sliding
pressure set point by the operator as there may be mismatch at that point
UCC Start up BMM(w)=>BFM(w)=>CC(w)=>CC(D)
SCRN

Most stable operation is achieved in this mode since boiler input is

directly adjusted but response to the MW demand is sluggish than CC /
BF mode since the main steam pressure is controlled by the turbine
governor valves and the MW is controlled by the fuel supply. But the
response to grid frequency variation is sluggish.

If CC mode is selected just after setting TM to auto, TM demand will

change the intended governor position and MS pressure set point will also
changes as per the sliding pressure curve. This results to disturbance in
the boiler

When the turbine master is changed to MANUAL mode while the unit is in
CC mode, the control changes to BFM ( Boiler master in Auto).

In other mode the set point for MSP is set by BID

BTG stable control APS

Initial Loading of TG is done in Load limit mode with target of 5% in TCS

Operator can change to GOV mode beyond 30% otherwise TG is in LL

mode

Since frequency deviation is corrected in UCC MWD, TG may run on LL

mode & no need of GOV mode

LL mode of TG is most stable if Freq fluctuates rapidly

UCC + LL mode is the most stable operation of BTG set
 Run Back in Power Plant

Load run back will occur when one of the multiple running
equipment is tripped:
Target Load in MW

Boiler Feed Water Pump 50% Load with 300%/min rate

CEP 50% Load with 100%/min rate

Forced Draft Fan 50% Load with 300%/min rate

Induced Draft Fan 50% Load with 300%/min rate

Primary Air Fan 50% Load with 300%/min rate

Air Heater 50% Load with 300%/min rate

Pulverizer 4 to 3 65% Load with 100%/min rate

Pulverizer 3 to 2 40% Load with 100%/min rate

When 50% runback operates & >=5 coal mills are in service ,Mill A
trips first if in service & after 1 sec Mill F trips in sequence with
first Mill-A then Mill-F .

During run back UCC -> BFM -> BI Mode / TFM

 Load Fast Cut Back

Load Fast Cut Back occurs when load MW > 20% & Generator or Turbine
trip & boiler master auto.

FCB occurs at 90 to 100% load => ERV opens for 10 sec

FCB occurs at > 60% load, BID comes to 60%

FCB occurs at < 60% load, BID is hold at the existing value

FCB occurs at 20% to 30% load, BID is set at 20%

HPBP valve opens fully during FCB

Transient increase in condensate flow may trip the CEP due to overload

LPTB valve opens quickly to decrease RH pressure: -> Much steam (heat)
flow to condenser -> Low vacuum of condenser is concerned .
 Load Fast Cut Back

Extraction stops: -> HP & LP heaters & deaerator stop -> ECO inlet
FW temperature down -> Exhaust temperature down -> Primary air
temperature down -> Coal dryness down -> Combustion stability
down -> Hence to keep combustion stability, ECO inlet temperature
needs around 160 deg.C -> Hence heat FW only in deaerator ->
Thermal stress in deaerator may increase -> If deaerator can't allow
thermal stress, heater#7 shall be operated (from CRH)

LPTB valve quick open logic to control the heat input to condenser

Boiler is in DRY mode: Not economical because boiler load is high

during house load or boiler island operation which is due to more
heat loss to condenser. Also no heat recovery by BCP in DRY mode.
Hence more heating steam is required to keep ECO inlet FW
temperature.
 Load Fast Cut Back FCB

FCB

MW HPTB VALVE OPEN

Fuel

Press TB VALVE

MW
Press
TB VALVE Fuel
Transient Load
HP TB_100% FCB

Generator Output MW Generator Output % HP TBV Outlet Temp (Ave) / 10 degC

HP TB Valve Position % HP TB Spray Water CV Position % 3ry SH Outlet Temp (Ave)/10 degC
2ry RH Outlet Temp (Ave)/10 degC Main Steam Press MPa MPa T-BFP(A) Outlet Press MPa
T-BFP(B) Outlet Press MPa

110 28

100 26
90
Gen. Output, TB Valve Position [%], Temp [℃]

24
80
22
70

Pressure [MPa]
60 20

50 18
40
16
30
14
20

10 12

0 10
13:10 13:15 13:20 13:25 13:30 13:35
Time (hh:mm)
 HPBP Functioning
HPTB
Max. Main
Opening at
Normal Steam
Max. Main MSPr at
Main Steam Pressure Max.
Boiler Steam Max. HPTB
Condition Pressure Control Mode Set Pt / Pos (Kg/cm2) HPTB
load Pressure Opening
(Kg/cm2) as reached at Opening
prevailing at (Kg/cm2)
per F(x) defined
defined
condition
condition
Wet Pressure Based on the MSP Set
Mode Control Point Curve (Series 1)
BACK UP
Dry MSP Set Point + 10 *
Pressure
Mode Kg/cm2 (Series 2)
Control Mode

Protection
100% 245.9 0.00% 267 17.70% 265.9
Close.
Protection
80% 190.4 10.00% 205 17.50% 204.3
Close.
MFT Protection
60% 138.8 0.00% 149.6 17.50% 148.6
Close.
Protection
40% 97.7 0.00% 109 20.00% 103.3
Close.
Protection
20% 86 0.00% 92.6 19.40% 87.8
152
Close.
 HPTB
Max. Main
Opening at
Normal Steam
Max. Main MSPr at
Main Steam Pressure Max.
Boiler Steam Max. HPTB
Condition Pressure Control Mode Set Pt / Pos (Kg/cm2) HPTB
load Pressure Opening
(Kg/cm2) as reached at Opening
prevailing at (Kg/cm2)
per F(x) defined
defined
condition
condition
Protection open at 100%
Boiler Pressure for 20 Sec (Auto Stand by
load Control Mode), then Pressure
control in AUTO Mode
Boiler ERV ( Set Pr 269.19
Island 100% 245.9 Kg/Cm2) force opens for 10 66.00% 269.1 100.00% 261.9
( 21 MW ) sec
80% 190.4 67.00% 210.1 100.00% 208
60% 138.8 100.00% 156.3 100.00% 154.6
40% 97.7 100.00% 107.5 100.00% 107.4
20% 86 38.80% 89.6 50.60% 87.3
FCB
Protection open at 100%
Boiler Pressure for 20 Sec (Auto Stand by
load Control Mode), then Pressure
control in AUTO Mode
ERV ( Set Pr 269.19
Turbine
100% 245.9 Kg/Cm2) force opens for 10 36.00% 269.5 100.00% 262.8
Trip
sec
80% 190.4 72.00% 211.6 100.00% 209.2
60% 138.8 100.00% 161.6 100.00% 156.3
40% 97.7 100.00% 109.3 100.00% 107.5
20% 86 50.90% 91.3 70.70% 88.2
153
 HPTB
Max. Main
Opening at
Normal Steam
Max. Main MSPr at
Main Steam Pressure Max.
Boiler Steam Max. HPTB
Condition Pressure Control Mode Set Pt / Pos (Kg/cm2) HPTB
load Pressure Opening
(Kg/cm2) as reached at Opening
prevailing at (Kg/cm2)
per F(x) defined
defined
condition
condition
On black out, All BFPS
Pressure Stop, therfore HTPB is
Control Protection close, till any
BFP comes into service.
Black ERV ( Set Pr 269.19
100% 245.9 0.00% 270.3 12.00% 265.8
Out Kg/Cm2) auto open
80% 190.4 0.00% 208.5 15.00% 204.6
60% 138.8 0.00% 151.8 16.00% 149.2
40% 97.7 0.00% 106.6 18.00% 103.9
20% 86 0.00% 89.2 16.40% 87.8

Boiler Island at Black Out

MFT Boiler Island Turbine Trip
100% Stabilized 154
Load Fast Cut Back
3850

Turbine Speed
3800
Turbine S peed (rpm )

3750

3700
Actual Test Data Simulation
3650

3600

3550
-60 -30 0 30 60 90 120 150 180 210 240 270 300

Time (sec)

155
 MS Temperature / Superheat during FCB
620 100

600 80
Temperature (℃)

Superheat (℃)
580 60
2ry Pa s s Inl et Superhea t

560 40
3ry SH Outl et Temperature

540 20

520 0
-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Time (min)

156
MS Pressure During FCB
310 120
Sa fety V a l v e Setti ng : 307.2 atg

300
HP TB Va l v e Openi ng 100

290
MS Pres s H i g h MF T Setti ng : 285.4 atg 80
Pressure (atg)

O pening (%)
280
Much margin to MFT set pressure because of 60
270
large capacity HP TBV
SH Outl et Des i g n Pres s : 269.2 a tg

40
260
Max：256.24atg
20
250
SH Outl et Pres s ure

240 0
-5 0 5 10 15 20 25 30 35 40 45 50 55 60
Time (sec)

157
 HRH Steam Pressure During FCB
RH safety valve float due to much steam flow through HP TBV, and slower opening of LP
TBV . ERV Operation :Load before FCB ≧ 90% : 10 sec forced open, Load before FCB ＜
90% : Not open

80 120

75
Max：72.08atg
100
70 R H Outl e t Sa f ety V a l v e Setti n g : 7 0 .8 a tg

65
80
R H Ou tl et Pre s s u re
Pressure (atg)

60

Opening (%)
55 60

50
LP TB V a l v e 40
45

40
20
35

30 0
-30 0 30 60 90 120 150 180
Time (sec)
158
HRH Pressure during FCB

80
75 RH Outlet Safety Valve Setting : 70.8 atg
70
65
HRH Pressure (atg)

60
55
50
45
40 ERV forced open is not necessary for
35 less than 90%
30
25
20
70 80 90 * HP TBV : Quick Open 100
Unit Load before FCB (%) LP TBV : PI Control
ERV : Not Open
159
APS Special Features

The Automatic plant start-up & shut-down system (APS) is

to perform the boiler and turbine plant start-up & shut-
down sequence:

The unit automation control is functionally divided into 3 levels,
APS, group and drive. (The group level is further divided into
main group and sub-group.)

Automatic Startup and shutdown commands for the functional
groups are given from APS.

HIGHEST
LEVEL APS
• <1> APS/UNIT MASTER LEVEL
GROUP GROUP • <2> GROUP/ SUB GROUP &
LEVEL /SUB-GROUP
CONTROL
SUB CONTROL LEVEL
• <3> DRIVE LEVEL
DRIVE CONTROL
DRIVE
LEVEL
APS Special Features: Start-up
• APS OPERATION PANEL (START UP) 1/2

APS AUTO
APS Special Features: Start-up
• APS OPERATION PANEL (START UP) 2/2

APS SEMI-AUTO
Pulverizer Inerting & Clearing

INERTING OF PULVERIZER after Coal Burner Trip (Emergency shutdown)

When the Coal Burner trips with residual coal inside Pulverizer, it is
important to cut out hot air and cold air, and to fill steam in the
Pulverizer for 2 minutes(initial set) to inert the Pulverizer.

The Pulverizer is isolated and inerted to prevent the Pulverizer fire

caused by spontaneous ignition of coal.

This function can be carried out when “ Inerting in Auto”.

If the Pulverizer clearing operation cannot be done immediately, it’s

recommended to refill the inerting steam every 30 minutes to
compensate the leakage of inerting automatically.
Pulverizer Inerting & Clearing
Pulverizer Inerting & Clearing

CLEARING OPERATION
After the Pulverizer trips, Clearing Operation of
Pulverizer is required to be performed to
discharge the residual coal inside the Pulverizer
into the spillage hopper with manual initiation of
push button of OPS.
Clearing Operation is performed with the
combination sequence of MBC and Pulverizer
Spillage ash handling system, and all operation
and monitoring can be done through OPS in the
CCR.
Pulverizer Inerting & Clearing

Clearing Select
Pulverizer Inerting & Clearing
INERTING

INERTING 120sec
Pulverizer Inerting & Clearing
CLEARING IN PROGRESS

After 180sec
10sec
120sec
Thank You