coapreR 1X (COUTROLS FOR ONCE-THROUGH BOILERS Before considering control requirenents for once-through boflers, it is instructive to examine sone of the physical aspects and differences associated with various types of stean generators ep Superheaters Turbine Superheaters Turbine perrea= merit pi \ 1 vi Boiler Feed Pump | | | | L FUGURE 9.1 FIGURE 9.2 4 Furnace Furnace wae Sai Furnace walls Figs. 9.1 and 9.2 are schenatics of the two basic types of steam generators in use today. Fig, 9.1 indicates the Fluié circuitry associated with the so-called conventions] or drun-type unit. In this systen the pressure level is always below the eritical point of steam, 3206.2 pst (ue., steam has latent heat). Feedueter 15 preheated in the econonizing section and flows into the drus, downconer, water wall or furnace circuit. Since steam generation occurs in the water well sections, and the recirculation flow rate around the furnace cireuit is Five to ten tines that of the generated stean ‘Flow, depending on the 1036 the unit 4s carrying, the water wall exit flow is a Tow quality mixture of steam and Tiquid, and the furnace circuit renzins essentially in e satureted condition at the ‘existing drum pressure. Mechanicel separators in the drun insure that negligible moisture is carried over into the superhenting sections. The steam is superheated to rated stean temperature conditions in the superheating sections and passes on ints the high pressure turbine.‘At this point sone cooments on the response characteristics and dominant effects which occur transiently in this type of unit are appropriate. Consider the response for e change in the turbine throttle valve position or equivalently, Toad. The increase in steam token from the botler results fn a decreasing boiler pressure, This decreasing pressure is arrested by increasing the steam generation in the furnace walls through increased fuel input. The Targe change in the specific volune of the fluid in flashing fron Tquid to steam is the physical mechanism by which pressure js restored. Note that changing feedwater flow results in essentially Just a change in drum Tevel. “Thus, in conventional units, conbustfon 4s used for pressure control, and feeéwster basically follows ‘the steam Flow to insure that an adequate supply of Iguid 4s in the boiler at 211 tines. ‘Another important aspect of this type unt, particularly fron an analytical wodeling standpoint, 4s the fact that the fluid properties and conditions in each section of the boiler under norma? operating conditions are well defined; that 4s, Tiguid in the economizer, saturation conditfons fn the furnace circuit and superheated stean in the superheaters. This permits the equations des~ certbing the fluid properties for a particular condition to be used throughout 2 given section (i.e., furnace circuit, superhester, etc.). without the complex problem of trying to describe the properties of the Fluid if it were to undergo drastic changes in properties in a particular subsection. Consider Fig, 9.2 which shows the fluid circuitry of the once-through bofTer. These units ray operate under subcritical and supercritical conditions (4.e., above 3606.2 psi). Note that the Flow of fluié through the bofler 1s continuous, and that as heat 1s added along the fluid path, the fluid properties change in a continuous manner ‘he pressure level in this type unit is basically specified by the flow being forced through the entire boiler circutt by the Feed pump. Changes in fuel input will have essentially a transient effect due to the expansion or condensation of the fluid within the boiler until the new operating conditions are achieved, Since these units operate in the higher pressure ranges, the changes in the fluid specific volune are relatively smaller than conventional units, thus diminishing the effect of heat addition on pressure. In this type unit then, feedvater has a dominant effect on pressure. ‘Another inportant difference in characterfstics and, hence, control requirenents of once-throush versus drun-type boslers relates to the fact thet the steady state flow rate of fluid in the furnace tubes for once-through boilers 1s proportionst to Toad in the normal operating range of 30 to 100%, whereas it is almost independent of load or of feedwater flow in the case of érun-type toflers. In drum boilers, changes in fecdvater flow or steam flow do not materially affect the ‘fluid Flow rate in water wall tubes and, hence, there is no concern of major isbalance betweenheat flux to the tubes and heat absorption to the inner fluid. For once-through boslers, however, 48 4s Smportant to keep a close watch between the once-thraugh flow rate, i.c., feedater flow and fuel Flow since only a few seconds of a major Snbelance can resuIt in rapid rise of tube tenper- atures and burn out. Fuel and feedwater flow must, therefore, be moved in unison and corrections {in the ratio of fuel to feedwater should be made within well-defined limits in a slow reset re- calibration node to correct for tenperature deviations: BOILER RESPONSE cHARACTERISTICS The important first step in the formulation of @ contro} philosophy and selection of a contro? configuration fs to obtain a good description of the plant's responses to various input disturbances. ‘These responses are often referred to as "plant open Toop characteristics". Figs. 9.3 through 8.6 extracted from reference 9.1 show the nature of boiler variables" responses to changes in turbine valve position, puxp speed, spray valve change and change in heat, flux in the gas path. ‘These response characteristics are for @ suberftical once-through bofler. A supereritica? botler wil? have essentially the sane type of response characteristics, with even stronger coupling between Feechater flow rate changes and pressure changes.TT REHEAT TVET. + FIGURE 9.3uw Seee0 sree FIoure 9.4TOF aie coreerreemnee | THRERTY RY han TER / MOTE TERETE CO a ey revs osenense ee Stance FIGURE 9.5FisuRe 9.6BOILER-TURBINE CONTROLS ‘The main objectives of bofler-turbine controls are: 1, To attend to the turbine denand: for energy as expediently as possible within the storage and auxiliary systen capabilities of the plant. 2, To mintain process conditions, pressure tenperatures and flow rates (Feedhater, fuel and air) at optimum and safe values under load demand disturbances as well as other upsets such as fuel disturbances, losses of auxiliaries, ete. ‘The dezands en contre! performance are obviously related to the severity of load change response solicited frome given steam generating unit. Several philosophies of contro? have evolves in attenpts to acconmodate the need or capability for rapid load changes versus the need ‘to control critical plant variables (temperatures and pressures). A review of these philosophies 4s appropriate as an introduction to principles of control of once-through bofler and in particular ‘the coordination of bofler-turbine controls. onvenTiona, paacTice ost conventional drun-type steam units are operated in the boiler following node wherein changes in generation are initiated by turbine control valves, and the boiler controls respond with necessary control ection upon sensing the changes in stean flow and deviations in pressure In this mode the turbine has access to the stored energy in the boiler and load changes within reasonable magnitudes occur with fairly rapid response, as shown on Fig. 9.7. This characteristic 4s beneficial from a governing standpoint Snproving the quality of frequency control, and it ts characteristic of conventional stean systens to maintain @ fairly narrow band of frequency due to this fast governor action.(®3) 1p 45 also beneficial in arresting frequency sags foTTowing Targe upsets, The bofler controls must be responsive and stable to withstand this mode of operation.{TURBINE FOLLOKING NODE ‘The turbine-foltow mode, on the other hand, involves use of the turbine control valves to regulate boiler pressure, This can be done with practically no tine delay so that under this rode boiler pressure suffers virtuatly no transtent deviations, and no use is nade of stored enersy in the botler. Steam flow through the turbine and, therefore, turbine power follows closely the anount of steam generation, {.e.. the input to the boiler. Contr! of hoster variables is easy under this mode of operation, although the response of turbine power 1s considerably slower. The units’ power output does, however, reflect both the intentions? and unintentional variations in fuel input which in the ease of coal-fired units can be a problen. ‘The turbine following mode 4s tacking in the main functional requirenent of a power plant which fs to meet electrical load demands as expediently as possible, Governifg action would be quickly washed out by the action of the pressure controls. Fig. 9.8 shows response characteristics of a turbine following plant where the change in Toad denend actuates 2 corresponding change in fuel and feedwater input, and the turbine valve maintains contant boiler pressure. The output power is delayed by the lags in fuel system and storage tine constants of the boiler. The dinension of the control task fs reduced appreciably as bofler input becones an independently specified variable rather than @ process dependent quantity involving Feedback. COOROTKATED BOILER-TURBINE CONTROLS, Recognizing the advantages and disadvantages of both previously discussed ‘odes of operation land control and the need for varying degrees of canpronise between the desire for fast response to lead changes and the desire for boiler safety and ood quality of control of steam conditions, ‘a Tosicel contro} mode 1s one that offers an adjustable blend of the two previously described schenes. This need for coordination of the boiler turbine is sore pressing in the case of fonce-through boilers where the process interactfons between feed pump, firing, and turbine valve are closer coupled than was the case with érus-type boilers with their large saturated Viquid storage and insulating effect of having saturation pegged at the ¢run.=e BOILER-FOLLOW MODE CHANGE IN TURBINE VALVE POSITION ‘A TURBINE POWER ‘A BOILER PRESS. —t-MiNs—> pe ° T 2 3 4 FuuRe 9.7 TURBINE~ FOLLOW MODE CHANGE IN FUEL INPUT CHANGE IN TURBINE POWER MINS > 0 ' 2 3 FIGURE 9.8 —— coat Fine GAS FIREDone A type of coordinated controls that has been deseribed in the literature 1s shown functionally fn the schenatic of Fig. 9.9. To achieve this coordination, it 4s necessary to make the speed changer motor respond to intelligence other than and in addition to load contro} signals. This, 4s done by integrating the Toad control pulses to develop signal indicative of denand for Mi wihich can be aTtered by other inputs, This signal 4s sodified by 2 frequency deviation bias natching the unit's governor droop characteristic to develop the desired Mi. Comparison with the unit's actual output develops the #W error. The desired "signal as well as the Mi! error signa? are sent to the bofler controts. Turbine speed changer position ts ¢irected to reduce a combination of Mi error and pressure error to zero while the boiler controls Tikewise are directed to reduce the pressure error biased by the 1M error to zero. The sense of the cross-coupled Mi error and pressure error biases is in the direction such that a positive Hi error (VW lower than denand) would cause the turbine valve to open and the bofler controls to call for more feedwater fuel ‘and air, whereas a positive pressure error (pressure lower than set point) would 311 for closing of the turbine valve while simultaneously increasing the feedwater, fuel and air. Analysis shows that the control systens cone to rest when both the Mi error and pressure errors are restored to zero and transiently the eross coupling is in the direction to attenuate interacting effects of the Mi feedback and pressure feedback Toops. Depending on the cross coupling strength between pressure and Mi Toops, the Toad response can be adjusted to any degree between that shown on Fig. 9.7 and that of Fig. 9.8. ‘Another variation of coordinated controls where the turbine valve 1s primarily the pressure regulator and boiler inputs are actuated basically fron load demand 4s to introduce a transient offset in the pressure set point from 1oaé denand, Kith such an arrangenent,on a step increase {in Yoad desand, the pressure set point moves down with a timed ashout causing the turbine valve to open innediately. ‘One inportant aspect of these methods 15 the role of the turbine valve as the basic boiler pressure regulator. Relying on turbine valve for this rote has drewbacks as follows: 1. Constant notion of speed changer rotor due to the normal process noise, fuel disturbances, fetc.y which can be significant in the case of coal-fired plants. Pressure deviations Would be eliminated at the expense of Mi deviations,Power Technologies, Ine. -2- 2, RelYance on turbine valves for pressure control resoves the incentive to do @ 20d contro! job on the bofler input variables. If responsibility for good and stable pressure control is not assigned to the boiler input variables, this can becone @ probten under the condition of valves wide open, at which point the turhine velves are beyond control range. 3. In those cases where a transient offset in pressure set point activated from load denand 4s not provided, the use of turbine valves for pressure control does rateriaNly reduce the lead response capabslity of the unit. [NPROVED METHOD OF SOILER-TURBINE CONTROL COORDINATION Keeping in mind the disadvantages of continuous pressure control by means of turbine valves land the over-all objectives of quick load response within reasonable limits of boiler storage capability, we have developed the schene of Fig. 9.10 which meets these objectives. The features of the configuration of Fig. 9.10 may be understood in the light of the following considerations applying to the basic schene of Fig. 9.9. The Ma Feedback oop without adequate cross coupling from pressure error presents stability land potentia1 runavay problens if for sone reason the boiler fails to keep in step with the denand ‘That 1s, without biasing action fron pressure error, the YM loop wiTl cause valve overtravel fn attempting to satisfy Mé demand, irrespective of boiler pressure. An anslogous situation occurs with the use of first stage pressure feedback, whereas this condition would be avolded if a suitable indication of valve position (if Tinear with flow) were used tsanine no the stgnifieance of coubining pressure error to the demand, To prevent fnter- Action of the presure and Toop, the gutn‘af the pressure bias ross cousting tem would be adjusted such that the turbine volve would wot attempt to correct the cangonent of I error due to the pressure not being at set pint, but wuld allow the pressure loop to ascomltah this component correction. Ths means that the cross coupling gnin wovtd be MK or the equivalent turbine valve opening. Since MM tn the steady state are proportions] to valve position visas pressure, the cnbination of Hi added to the negative pressure error guined by the noninteracting value (Fig. $10) which 4s prorttona! to oad evel, cin be Interpreted as turbine valve opening, i.e.-a- Wl = KP + Kyl. * Fe) (= HPQ) = Ko were K, 1s proportional to valve opening, Py = pressure set point and P, = pressure error. To the extent that the pressure error cross coupling term is gained by K,, the combination of Wi and this pressure error term can be replaced by the equivalent turbine valve opening. Any added strength of this pressure error beyond K, inhibits turbine response and provides sone degree of pressure regulation by means of the turbine valves. In view of the above considerations and in keeping with basic philosophy of taking advantage of stored eneray in the botler within safe Tinits, the schene of Fig. 9.10 accomplishes the required degree of noninteraction between the Mi loop without inhibiting turbine valve moton as ‘ong as pressure error is within a safe band. The response of this system to Toad denand pulses as well as to governing signals through the turbine {s compatible with that of conventional units exhibiting fast response for infted changes, This type of response fs also compatible with dynamics of loed-frequency contrels. As shown on Fig. 9.10, the Toad denand, which can be derived either from the Tosd control signal or set manually, establishes the desired turbine demand index (TOI) which is equivalent to turbine valve position. This index 1s derived fron first stage pressure by multiplying it by the ratio of pressure set point to actual pressure. It fs, therefore, the first stage pressure that would result for the given valve position at the pressure corresponding to pressure set point, Aside from convenience of measurenent, this index avoids the nonlinear relationship between valve position and flo, end thus forms an ides! feedback signal instead of actual valve position, which was Inentioned previously as being desirable. Essentially, TOI is a direct measured indication of the turbine Flow denané compensated for throttle pressure deviations from set point. he difference between denend and actual TOI acts on the speed changer controller to move the turbine valves. The desand signal for TOL 1s slowly calibrated by integrated MM error from denand. This has no significant dynamic effect and is a conventent Feoture especially under base Toad operation were a Mi cenand Yevel can be set and the proper TDI will be calleé for regardless of condenser, heater and other conditions which may affect the steady-state relationship between TDI and-ue FREQUENCY SPEED Mw ACTUAL, a ‘TURBINE free! GOVERNOR laras vege | My <= - if Loao i ERROR ._ [PROP g TURBINE DEMAND + + g. jeer] T VALVE SPEED CHANGER | POS. CONTROL = DEMAND FOR |__» Feeowarer BOILER | ——» FIRING RATE ‘CONTROLS| re fo-> ere Tsornen weasuneo VARIABLE S ANTICIPATORY FEED- FORWARD ACTION FROM DESIRED MW COUPLING OF TURBINE LOAD CONTROLS WITH BOILER CONTROLS Fieure 9.9-15- FREQUENCY ACTUAL, (ERROR FEED FORWARD uw eo SIGNAL TO. tr BOILER CONTROLS BIAS. | PRESS, THROTTLE Pe cat 7 | cruraive oemano) nt gro LOAD ~e DESIRED INDEX PRESS, a re | tor acrua, ie | P LAA) Trent io guancer roe GAIN. WITH ADJUSTABLE DEADBAND PRESS, ERROR (Psp PD CONTROL SYSTEM COORDINATING TURBINE LOAD DEMANDS WITH BOILER PLANT CAPABILITIES FIOURE 9.106 Pressure error, Sf within an adjustable deadband, does not inhibit turbine valve response. However, if an excessive pressure error occurs, indicative of changes in Toad in excess of botler capabilities, this error will act to regulate pressure with @ fairly narrow proportional band. ‘This controt action fs governed by the deviation of the actual pressure from the pressure set point + the pressure deadband such that the action is ssooth, coming in and going out of operation. ‘The value of the deadband can be adjustable. For the case where the fuel systen {s responsive and reliable (of1 and gas), @ large deadband (+100 psi) can be safely used. On the other hand, should the fuel systen exhibit frequent upsets, such as pulverizer plugging, etc., it may be necessary to reduce this deadband to a lover value in the interest of plant safety. (COORDINATION OF FUEL AND FEEOWATER coNTROLS Unlike conventional steam generators, the once-through unit does not have @ large reservoir of recirculating liquid in the vaterwalTs or bofling regfons of high heat absorption rate, thus raking then nore subject to burnout conditions. Tt is therefore tnportant that a reasonable balance betueen feecnater flow and heat input into this region be maintained. This requtrenent 4s the source of difficulty in the practice of basieally firing the once-through unit to maintain throttle temperature with a conbination of feedforward and feedback action while maintesning pressure with the feedwater contro! Toop, Transient misnatches using this baste philosophy can be severe, tending to burn out conditions when feedwater starvation with excess fuel occurs and tending toward positive feedback pressure effects when an excess of feedwater to fuel causes depressurization resulting in further increases in feedwater flow. It thus becomes necessary that the feedwater and fuel controls derive thefr primary denand signals fron the sane origin where only the dynamics of relatively well-known auxiliaries will cause mismatches for which compensation can be provided. The provision and continual use of runback controllers to provide this protection fs unreliable, complicated, results in poor and unpredictable control action and 4s in general an undesirable control policy.Si CONTROL AND COOOROINATION OF BOILER INPUTS Whether or not recourse 4s taken to continuous use of turbine valves to assist the boiler control {and this 1s controtlable by the setting of the deadband on the cross-coupled pressure fervor), the fundamental requirement for successful once-through bofler contrals 4s the proper transient coordination of the inputs to the boiler, nanely, feedater flow, firing rate, spray Flow and gas distritution dampers. The need for close match of fuel and feedwater in once-through boflers dictates that the dominant comand to these two subloops be from the sane scurce, and other corrective action to alter the ratio of fuel to feedwater should be of @ slow Vinited nature. Af the only objective in contro} were to regulate pressure and temperature without concern for keeping fuel and feechater transiently in step, a configuration such as in Fig. 9.11 would be adequate. Basically, the pressure controls, operating on pressure error, set the denané for feedwater flow, There is no particular need for anticipatory action for this loop since the pressure error ives an indteation of the integrated flow deficiency or surplus in addition to the almost instan- ‘taneous deviation proportional to load change. This instantaneous pressure deviation following a change in velve opening is proportional to the load level. It is an inherently adaptive process characteristic since the change in fluid storage in the boiler for a given change in load 4s approximately proportions] to the Yoad level at which the change occurs. Pressure error is thus fan inherent self-adepting process intelligence which can be used effectively in feedback ‘configurations. In the configuration of Fig, 9.11, the primary action to the fusl and air controls fs derived from the desired turbine danand index through a proportional term and a rate term to account for changes in thermal stored energy in the boiler. Feedforward action for the fuel and air 15 necessary since indications fron temperature error would be extrenely tardy. Steam temperature error operates with proportional and rate action on denand for tenper- ature after spray. A cascaded Toop controlling temperature after sprey moves the spray valves to yield very effective transient control of main steam temperature. A slow reset controMer operating on error between spray valve position and a desired valve position (50%) restores the spray valve to set point by modifying fuel and air demand. This denand 1s also modified18+ by slow reset action on main steam tenperature to provide final trimming for proper balance between firing rate and feedwater flow. ror LE |PULSER }-e CHANGER posse iets PRESS. PROP) DEMAND FOR +3 PROP] . Sep ce 1G recowarer eset pan seeeo press. DEWAND FOR FUEL AIR rw rene raasere abe puma —eebesy 7 rma ALE arren| ~ Ca Tene dave” | Temp AFTER SPRAY EXAMPLE OF CONTROL CONFIGURATION WHICH PERMITS TRANSIENT WISHATCHES OF FUEL AND FEED MATER FIouRE 9.1118. [Mthough the configuration of Fig. 9.11 ean be adjusted for good control of pressure and tenperature, it 4s lacking in the important requirement of close matching between firing rate and feedwater flow to avoid damage to the furnace circuits. As can be seen fram control performance shown on Fig. 8.12, there 1s considerable transient mismatch between feedwater flow and firing rate, The difficulties associated with this schene relate to making firing rate and feedvater flow foliow each other when each 1s under the influence ef different prinary signals, (pressure controller output for feeduater end TOT denand for fuel and air). Reliance on runback controTlers ‘to keep the two variables in step with each other did not yield satisfactory results. haste REST he 4 veo FucurE 9.12-2- FUEL AND TENPERATURE CONTROL COORDINATION ‘The most effective and expedient means of temperature control by far is through the well ‘accepted and proven means of desuperheating spray. It 4s therefore reasonable that this means of temperature control be relegated the responsibility of controTling temperature deviations under transient conditions. It should be noted, however, that spray control fs only & means of tran- ently redistributing the energy Tevels in the bofler and wiTl have no effect on the steady- tate throttle conditions for 2 given total feedwater flow (i.e., through flow plus spray flow) ‘and fuel input, Thus, final trimming to attain a desired throttle condition and Toad (1.e.5 ‘Flow) must be done through the fuel controls. Since the spray control ‘is so effective, this triening contro! action may be in the form of relatively minor control action on fuel derived from tenperature error. Aithough spray 1s effective in temperature control, caution must be exercised to insure that the control capscity or Tinit of the spray systen is not exceeded by excessive transient duty. In order to insure that the spray valve renains in control range, additional intelligence to the fuel systen sust be provided to indicate the extent that an additional or deficfent anount of spray is necessary to maintain required throttle conditions. The deviation of the spray flow fron its noreal midcontro} range value may be interpreted as an equivalent change in fuel demand required to eliminate excessive spray flow deviations and to bring the spray back to its pre- seribed midcontro} range value. Since the change in pressure head across the spray valve and the amount of spray required at a given flow are essentially compensating effects, the deviation of the spray valve fron its prescribed midcontrol range position forms a desirable ang direct indi- cation of the required modification of fuel demand to eTiminate spray flow deviations fron its prescribed value, which {s @ fixed percentage of through flow. ‘he need to use information on spray valve deviation fran set point (mid range) to modify {fuel and air denand can be demonstrated in simulation runs where no use of this information ts ade to nodify fuel, In these runs tesperature controt will be excellent for several minutes nti? the spray valve runs out of control range and then large deviations follow. This fs understandable since in the Vimit, if perfect control could be achieved by means of spray valve action, the tenperature error would be essentially zero and there would be essentiaTly no jnforsation to modify fuel through the tenperature controlTer.-a- 1t should also be noted in the spray control in Fig. 9.11 that in steady state the tanper- ature after spray 4s required to return to a prescribed fixed value. This imposes a constraint fon the tenperature control systen which cannot be satisfied if the spray valve fs to be reset to a given position. The result will be a slow and sustained osciTlation of the throttle tenper- ature as the reset action from spray valve position interacts with the reset actfon of the temper ature controler. This is corrected by feeding back rate of change of temperature after spray with @ slow washout rather than temperature after spray. This same basic philosophy of main steas tenpersture contro} can be applied with the use of ‘enperature difference before and after spray as intelligence in lieu of spray valve position. PREFERRED CONFIGURATION The problens of the configuration of Fig. 9.11 are avoided in the arrangenent of Fig. 9.13, where a comon prinaty denand signal for feediater and firing rate is derived from the pressure controls, In Fig, 913 we have included in dotted Vines @ feedforverd signal from TO! demand or from TOT, contrfbuting to the denand for feecwater fuel and air. Sone advantages of using this feedforward signal result from the reduction in the anount of reset action needed from the pressure controls making it somewhat easier to obtain stabiTity for ‘these controls. ‘The reduction of integral action and feedback gains in the pressure controls for the case here proportional feedforward from TOI 1s used makes these controls less responsive to other Upsets. However, unlike the case of pressure control on coat-fired drum type units where un= ensured upsets frequently occurring in the fuel systen cen only be corrected through action fron pressure error (Ref. 3.1.) the reliability of the feedwater flow subloop makes sinilar pressure upsets less significant in the once-through case where pressure contro} 1s primarily through feedwater flow. ‘A feedwater signal from TOI to reheat damper position, also marked in dotted Tines on Fis. 9.13, wat included in studies of control performance, but was found to be hermful in increasing transient deviations of reheat tenperature. This is because of the complex nature of the reheat tenperature transient which cannot be mininized by a sinple proportions} feedforward action on the danper. ‘The danper actually has to go through a down and up and then down notion to mininize the temperature error, and the end point of this trajectory (InteTligence fron proportional feedforward action) 1s of Tittle importance in mininizing the peak deviation in tenperature.igure 9.13+B. Fig. 9.14 shows control performance predictions for a ranp increase of 5% min. for 5 mins. starting from 36% load point for a once-through subcritical unit, FIGURE 9.18=u ANTICIPATORY ANO SAFETY FEATURES For the sake of clarity, we have rot included in the diagram of Fig. 9.13 a number of secondary features which are normally part of the control systen. These features are generally detailed in drawings outlining the hardvere layout. Anticipatory compensation for feechater enthalpy changes are provided by autonatic calibration lf the fuel dexand signal. This calibration through @ multiplier provides the right compensation independent of the flow rate and can be calculated quite accurately based on the feedwater enthalpy deviation relative to the total enthalpy pickup of the main steam in the boiler. Other features include load demand runback action fron controTlers monitoring the error between feedwater and feedwater denend as well as fuel cutback action based on the monitoring of the fuel to feedwater ratio, and fuel to air ratios The use of the Op meesurenent has been shown in & conventions] arrangenent with © controller acting on 0, deviatfons fren set point to modify the air denand through a multiplier (ratte). Although this is @ perfectly acceptable schene, especiatly for drun-type boflers where the correct anount of fuel is being continuslly maintained by pressure contro? action, we belfeve that in the case of coal-fired once-through botlers, deviations in Op are nore likely to be due to fluctuations in the fuel which can persist for @ Tonger tine unt] tenperature control correction can act. Hence, it would appear preferable to use 0, controtler action to modify, within limits, the fuel denand rather than the air denand. ‘STARTUP CONTROLS ‘The need to have recirculation through the furnace tubes at Tow flow rates end the process of pressurization to keep fluid below the boiling point and varfous other requirements of texper- ature matching during turbine rol) place special contre! requirenents for once-through boilers involving nanipulation of boiler throttling, bofler extraction, superheater bypass and other valves. ‘an exarple of the control requirenents will be given based en e superer‘tical once-through design by Conbustion Engineering. Fig. 9.18 shows a simplified flow diagram of a Conbustion Engineering supercritical boiler, including the startup water separator and the valves associated with it. Also, note the condensate donineralizer in the nain flow path. This is a full flow dentneratizer system, which is necessary-6- for continous water cleanup. The startup of a supercritical boiler involves the operation of the water separator (sonetines called flash tank) and the startup valves. The CE conbined circulation systen utilizes a low through-flow capacity startup systen. water wal] protection 1s attained by the use of the botler circulating pumps which provide enple flow through the water walls by recirculating during the startup phase. The feedwater flow is generally set at a nominal 5 For either hot or cold startups, the boiler is filled and vented up to the BT-6T5 (boiler throttling and throttling bypass) valve complex. At this tine water wall pressure is controtled by botler extraction valve BE. The water wall pressure set point is gradually increased as funct{on of water wall temperature fron an initial 1000 psig to 3500 psig. The firing rate fs adjusted to 14 ft the furnace exit g25 temperature to 1000°F with the additional Timitation that ‘the water wall outlet tenperature rate of change does not exceed 400° per hour As the water wall outlet tenperature increases, steam will start to flash in the startup ater separator. This steam is initially discharged through the SP (spillover) velve into the condenser. At the discretion of the operator, the steam is emitted to the superheater through the stean adnissfon SK valve, This steam cools the superheater sections and warms the main steam 1ines. The stean and water mixture exists through valve $.0. (steam drain). By proper ranipulation of SP, SD, and SA valves, a close match of steam temperature to turbine metal tenperature can be obtained and the turbine can be rolled when proper pressure and temperature conditions have been achieved. Desired stean pressure for rolling the turbine may be obtained hy adjusting the startup separator pressure set point which modulates the SP valve as a simple back pressure control. The water drain valve MD functions as 2 Tevel control valve for the water separator. When the turbine has attained full speed and is uniformly heated, the feeduater flow may be increased to 10: to provide for adequate steam flow for synchronizing and initial loading of the turbine generator, After synchronizing, SO valve 4s closed and the firing rate is increased to yield opproximately 785° water wal1 outlet tenperature at which point the separator "goes Gry", i.e., 211 fluid passing through the BE valve flashes to steam and fs re-adnitted to the superheater through the SA valve, When this condition is achieved, the control of water wat pressure is transferred from the BE valve to the boiler throttle bypass valve BTS. The BE valve+26. FIMisHts SUPHTR SUPHTR CONDENSER VETER LP ‘SEPARATOR OTNDENSATE WATERWALL: PULIPS 2-COILER, CIRC. PUMPS BOILER FEED HP HEATERS RO. 687 BOILER TURBINE CYCLE CE SUPERCRITICAL FIGURE 9.15 45 then closed and the unit thereby achieves once-throush operation. As Toad on the unit is ‘increased (increased flov) the BTB velves are unable to contro} the water well pressure and the BT (bot er throttle) valves open causing the BTE vaive to close. There are several BT and BTS valves in parallel. When the BT vatves are at? open, the 878 vales will again be opened. The TB and BT valves control the furnace water wall pressure above critical pressure ot all tives. During this initial loading operation and up to a Toad index of approximately 20%, the turbine contro} valves are placed in a fixed position corresponding to this 30: load point. Therefore, uring this period, generation is 2 function of the throttle stean pressure rether than the turbine valve position, Steam pressure reaches approxinately 3500 psig at 30% load. After ‘this point, turbine control valves participate in the control of generat fon. Generation '00/- a sok 0 1 . L L 900 SH OUTLET TEMPERATURE 800} ‘RH OUTLET 700- Ld L L 1 3000 PRESSURE 2000/~ SH OUTLET, PSI 1000} a a oF 30) 4 ‘AIR FLOW 20H! FUEL FLOW 10H tc] r ‘ e 1 z Sour] 5 6 START BOILER | _ TiWe-HOuRS| SySTEUS ROLLING TURAIE SYNCHRONIZED WARM STARTUP AFTER 11-HOUR SHUTOOMN 500-Ha SUPERCRITICAL UNIT-OIL FIRED FIGURE 9.16eres 9.1 9.2 9.3 4 9.5 9.6 9.7 9.6 9.9 -2- ces Amer, 0.3.5 de NelT0, F.P., Dyer, C.€., and Sumer, C.V., "Analysis and Design of Controls for a Once-Through Bofler Through Digital Simulation", ISA 9th Power Instrumentation Symposium Proceedings, 1965, pp. 11-30, de Mello, F.P., and Paulson, R.E., "Simulation of Plant Dynamics and Design of Plant Contro? Systens", presented at Southeastern Electric Exchange Meeting, New Orleans, LA, April 14-15, 1966, de Mello, F.P., Concordia, C., Kivetmayer, Lik. and Schulz, R.P., "Effect of Prine Hover Response and Governing Characteristics on Systen Dynamic Performance’, Anerican Power Conference, 1966. de Hello, F.P., and Ewart, D.N., "VM Response of Fossil-Fueled Steam Units”, TEEE Working Group on Power Plant Response to Load Changes, Joint Power Generation Conference, Septenber, 1972. CE Coordination Control Systen for a CE-Sulzer Combined Circulation Steam Generator: Price, L.V.5 Hunter, R.H., and Morse, R.H., "Control System Considerations for the £75 Mi Lignite-Fired Big Sroun Steas Generators", 1SA Power Instrumentation Symposiva, May, 1972. Durrant, O.W., Loeser, JK.» "Bofler-Turbine Control System for Application to Universal Pressure Botlers*, IEEE Conference Paper CP 63-1910 presented at National Power Conference, Cincinnati, Ohio, Septenber 22-26, 1963. "Development of an Advanced Argersinger, J-1., Laubli, F., Boeglt, E.F., and Scutt, €. Controt system for Supercritical Pressure Units", IEEE Conference Paper CPE3-1809, presented at National Power Conference, Cincinnat, Ohio, Septenber 22-26, 1963. Morgan, M.S.» and Grimes, A.S.5 "Load-Frequency Control of Supercritical Units on the A.E.P. systen", IEEE Conference Paper 31 CP 66-59, presented at 1966 Winter Poner Meeting, New York, Genuary 31 ~ February &, 1966 ‘Adams, du, Clark, O.R., Louis, J-R., Spanbauer, J.P., "Mathenatical Modeling of Once-Throuch Boiler Dynamics", TEEE Transactions, PAS-Bt, February 1965, p. 146.