CONTROLS

HRSG TRAINING
BENI SUEF, BURULLUS & NEW CAPITAL
WILLEM JAN DOMENIE & MARTIJN VAN GAMEREN
NEM ENERGY BV

21050/51/52
CONTENT

1. General

2. Closed loop
a) IP & LP Drum level control
b) Temperature control preheater
c) Temperature control steam

3. Open loop
a) Shut off valves
b) Steam line automatic drain
c) Stack damper

4. System protection
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GENERAL

Controls objective: maintain the physical conditions in the system within

required operating conditions

Consist of: measurement (signals), a control

program (logic) and means to influence the
process

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GENERAL

Controls objective in HRSG:

Supervision from the Central Control Room

Start-up (manually initiated from “ready to start”)

Normal operation

Normal shut down

Emergency shut down (HRSG trip)

Designed to follow the GT load unrestricted

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GENERAL

Types
Open loop control: control action is independent of output of the system

Example: Bread toast

Control action: time
Output: toasted bread

Closed loop: output has effect in the input

Example: Air conditioner

Control action: Cold air
Output: Temperature in room

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CLOSED LOOP
DRUM LEVEL CONTROL

Objective: maintain drum level

within limits

Why?
Steam system damage
1. To protect damage to the Maximum
evaporator and superheated due Level
to insufficient water & steam NWL
Minimum
Level
Evaporator damage
2. Protect steam system
(Superheater and ST) damage
due to water carry-over
IBD

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DRUM LEVEL CONTROL

How?
• Regulate Feed Water flow with the FW control valve
• Dump excessive water with Intermittent Blow Down (IBD)
SUPERHEATER

SUPERHEATED
STEAM
DRUM
LT

EVAPORATOR

HRSG FEEDWATER

CONTROL VALVE IBD (Intermittent blow down)

ECONOMIZER
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DRUM LEVEL CONTROL

Set points

• Start-up:
HRSG at start level
Allows the drum to contain the swell
(quick increase in drum level) NWL

• Normal operation:
Start level
Normal water level (NWL)

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DRUM LEVEL CONTROL

Start-up

LC
Drum level measurement used until
NWL (normal water level) is SUPERHEATER
achieved
FC
One-Element Control SUPERHEATED
STEAM

EVAPORATOR

HRSG FEEDWATER

CONTROL VALVE
ECONOMIZER

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DRUM LEVEL CONTROL

Until steam flow reaches

15% of Maximum
Continuous Rating (MCR): LC

FC
Level
High
NWL
Low
EVAPORATOR
Time

HRSG FEEDWATER

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DRUM LEVEL CONTROL

When steam flow reaches

15% of MCR:
+
++ LC
3 element controller used:
1- Level
2- Steam Flow
FC
3- Feed water Flow

EVAPORATOR

HRSG FEEDWATER

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 DRUM LEVEL CONTROL

Effect of 3 element control:

Level +
++ LC
High
NWL
Low
FC

Time
Level
High
NWL EVAPORATOR

Low
HRSG FEEDWATER

Time
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TEMPERATURE CONTROL PREHEATER

Objective:
Maintain condensate temperature at
the inlet of the preheater above the
water dew point (condensation of
water)
Maintain entrance temperature into
drum below boiling point
Why?
To prevent water dew point corrosion
on condensate preheater (CPH) tubes
To prevent steam formation in
economizer/preheater

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TEMPERATURE CONTROL PREHEATER

Condensate temperature is too low, so it is raised above dew point via

recirculation (pump and control valve)

Example:
Condensate T= 40°C
Inlet T at PH has to be 100 °C

T
40 °C 100 °C 175 °C

CONDENSATE
PREHEATER

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TEMPERATURE CONTROL PREHEATER

If temperature at the outlet of the PreHeater (PH) is too high, cold bypass

Example:
PH T= 190°C
Outlet T at PH has to be 175 °C

T
40 °C
CONDENSATE
100 °C 190 °C 175 °C
PREHEATER

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TEMPERATURE CONTROL PREHEATER

Closed loop temperature condensate/feed water:

T T

CONDENSATE
PREHEATER

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TEMPERATURE CONTROL STEAM

Objective:
Keep main steam temperature within
limits required for steam turbine (ST)

Why?
To avoid too high steam temperature
which can
• Reduce lifetime
• Damage the steam system

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 TEMPERATURE CONTROL STEAM

Attemperator between SH2 & SH3:

Attemperator 1

HP Steam SH 3
SH 2
Steam Turbine

SH design for certain load Load changed T=600 °C

Temperature (°C)

Temperature (°C)
SH 3
T=580 °C T=580 °C
SH 3 (set point) (set point)
SH 2
SH 2

SH 1 SH 1

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TEMPERATURE CONTROL STEAM

Attemperator between SH2 & SH3:

Attemperator 1

HP Steam SH 3
SH 2
Steam Turbine

Temperature, °C Attemperator between SH2 & SH3

T=580 °C
SH 3 (set point)
SH 2

SH 1
Attemperator

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TEMPERATURE CONTROL STEAM

Steam temperature control by regulating the spray water flow

STEAM TURBINE

HP Steam
SH 3 TT
SH 2
1 sec 2-3 sec 1 sec
≈5 sec

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TEMPERATURE CONTROL STEAM

Master/slave control

Master & slave control shortens response time, making control more stable

≈3mili sec
TT

STEAM TURBINE
HP Steam
SH 3 TT
SH 2
Slave ctrl

Feed forward

Master ctrl

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TEMPERATURE CONTROL STEAM

To ensure all droplets can evaporate in time (= before next bend)

• Minimum amount of superheat in the steam

To ensure sufficient atomization of droplets

• Minimum opening position of control valve

To prevent continuous start/stop of the attemperator control

• Attemperation start: setpoint + 3 °C
• Attemperation stop: setpoint – 1 °C

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 ATTEMPERATOR: ON AND OFF
Steam temperature (°C)

Attemperator: Attemperator: Attemperator: Attemperator:

OFF ON OFF ON

583 °C

580 °C
Set Point
579 °C

Time (minutes)
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ATTEMPERATORS

Beni Suef, New Capital and Burullus main steam line:

Normal operation Start-up

Attemperator 1 Attemperator 2
STEAM TURBINE

HP Steam
SH 2 SH 3

- Purpose of start up attemperator 2 is that at start of HRSG the steam it produces is

hotter than the steam turbine can handle. Even at full capacity of attemperator 1.
- When ST has started up, it can handle higher steam temperature and attemperator 2 is
no longer needed.
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OPEN LOOP
GENERAL

Types
Open loop control: control action is independent of output of the system

Example: Bread toast

Control action: time
Output: toasted bread

Closed loop: output has effect in the input

Example: Air conditioner

Control action: Cold air
Output: Temperature in room

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OPEN LOOP
Example:
Conditions:
Permissive
Permissive: need to be fulfilled at all Regulate flow when upstream temperature is
time to operate the open loop control at least 80 °C

If T = 70°C
When permissive is satisfied the command
will be carried out

If T = 81 °C

Protective: Safety of process or people. Protective close the valve when T > 90 °C
Always carried out Always when T >90 ° C
Alarm is generated

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ATTEMPERATOR SPRAY WATER SHUT OFF VALVE
Why?
Objective:
To make sure no water is coming into
Isolate the attemperator from the
the steam line.
feedwater system.
Most control valves can not guarantee
to fully stop flow.
Attemperator

HP Steam

SH 2 SH 3

STEAM TURBINE

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ATTEMPERATOR SPRAY WATER SHUT OFF VALVE

Permissive OPEN valve Protective OPEN valve

Control valve closed None
Protective CLOSE valve
Permissive CLOSE valve
Steam flow too low AND attemperator control
Always present valve not closed within 30 sec
Attemperator

HP Steam

SH 1 SH 2

STEAM TURBINE

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STEAM LINE AUTOMATIC DRAIN

Objective:
Steam line
Remove water from steam line
Normal operation
Valve opens:
Dripleg temperature < 10 K above saturation Drip Leg

Valve closes: Valve

Dripleg temperature > 30 K above saturation
M

See next slide

Standstill
To BD tank
Valve opens for 1 minute every 2 hours

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 STEAM LINE AUTOMATIC DRAIN

Drain Open Drain Closed Drain Open Drain Closed

Steam temperature (°C)

Tsat +30 °C

Tsat +10 °C

Tsat at
system
pressure

Saturation Temperature (Tsat) is calculated from the measured

steam pressure at that moment in time

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STACK DAMPER

Objective:
Open or close the stack damper

Why?
1. Limit the heat loss from the HRSG
when GT is out of operation
2. Prevent rain water entering HRSG
when out of operation

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STACK DAMPER

Permissive OPEN valve Protective OPEN valve

Always present None
Permissive CLOSE valve Protective CLOSE valve
Diverter damper closed or GT speed <100 rpm None

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HRSG SYSTEM PROTECTION
HRSG SYSTEM PROTECTION
Signal condition of measurements
Voting logic for important / safety measurements:
• 2 out of 3
• 1 out of 2
• Analogue & Binary

In case of too much deviation: alarm

Operation continues when minimum level of reliable information is
available. Operator action is required.

When measurements are not reliable, the HRSG will be tripped by closing
the bypass diverter damper valve towards the HRSG.
In worst case, the GT will trip as well.

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HRSG SYSTEM PROTECTION

Signal condition of measurements

Functioning of controls depends on correct signal of measurement

Problems arise when:

• Signals become unhealthy (bad quality)

• Multiple measurements of same process value deviate beyond

acceptable tolerances

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HRSG SYSTEM PROTECTION

3 measurement: logic 2 out of 3 voting

L1 No HRSG trip
Single failures may occur but will not result
in unsafe conditions L2 HRSG trip
HP Separator
L3 HRSG trip

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HRSG SYSTEM PROTECTION

HRSG trip

Fast closing of the diverter damper:

HP Feed water flow < LL more than 20 seconds

HP Separator outlet steam temperature >H more than 30 minutes

>HH

HP Separator level >HHH more than 2 seconds

Stack damper Not open

Drum level >HHH more than 2 seconds

<LLL more than 2 seconds

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MORE INFORMATION

More information can be found in:

NEM HRSG system description (21050+51+52-107-01)

Siemens System Descriptions

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 QUESTIONS

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