Introduction to

Auto Control Loops in Thermal Power Plant

A presentation for NPTI, Neyveli

Sith.Ananda Kumar,
Assitant Executive Engineer,
Thermal Power Station-II,
Neyveli Lignite Corporation.
 Automation

Preprogrammed execution

Less or no manual intervention

Time driven or event driven

Based on Protection and Interlocks

Control loop

Auto / Manual

Closed / Open

Critical / Non-Critical

Local / Remote

NPTI
Controller Action

On / Off

Proportional / Integral / Derivative

Feedback

Feed forward

Ratio Control

Split Range

Cascade

Controller Types

PLC / microprocessor / Microcontroller / Electronic

Distributed / Centralised

Hydraulic / Pneumatic / Electrical

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 Elements of Control Loop
Controller

Process
(Decision)

Measurement System
Measurement

Final Control Element (Process Variable) Action
(Final Control Element)

Human Machine Interface

Controller / Program
Process

Necessity for Control Loop

For Optimal operation of process within range

Sequential execution cannot be applied always

Quick response / High sensitivity

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Terms related to Control Loop

Set Point (Desired Value)
- Auto- Depends on Process flow
- Manual – Set by operator

Controlled Variable (Process Variable)

- Parameter in process taken for consideration
- e.g.,Deaerator Pressure / Hot well Level

Manipulated Variable
- Parameter chosen to vary in order to achieve desired set point
- e.g., Damper position / TCV position

Control Deviation
- Error signal that describes difference between SP and PV

Command Output
- Output to Final control element to correct the deviation

NPTI
Desk Control Tiles;-

%
100 100
HPH6 to DEA / LPH4 50 50
0 +20
2LCV553_063
% -20
-20 0 +20 0 0

VALVE COMMAND /
10 % POSITION DEV

0 100

48.15 % 0
+50

168 175
mmWc
PV SP -50
AUTO / MAN

M A SET POINT

CLS A/M OPN

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Execution of a Control Loop

Control Task
(e.g., SH / RH steam temperature control)

Variables to be measured in order to monitor stable performance of loop
(e.g., Drum level & Pressure / Feed water flow & Temperature /
Steam flow, Pressure & Temperature )

Selection of manipulated variables
(e.g., FCV position / Scoop Position)

Tuning of control loop / best control configuration
(Gain adjustments- Proportional / Integral)

Adjusting the manipulated variable based on information/signal received
(Command output from controller based on error signal.)

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Control Loops – Steam Generator

Furnace draft control
Superheated steam temperature control

Secondary air header pressure control
Reheated steam temperature control

Fuel oil supply header pressure control
Load and combustion control

Fuel oil temperature control
Auxiliary steam pressure control

Fuel oil flow control
Auxiliary steam temperature control

Atomising steam header pressure control

Secondary air flow to oil burner control

Hopper air flow control

Mill outlet temperature control

Feedwater flow control

Air heater average cold end temperature control

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Control Loops – Steam Turbine

BFP Scoop Control
CEP minimum recirculation flow control

LP Heater 1 level control
MST to Ejector pressure control

LP Heater 2 level control
BFP Seal water temperature control

LP Heater 3 level control
Gland steam pressure control

LP Heater 4 level control
Gland steam temperature control

BFP recirculation control
H2 cooler cooling water temperature control

Deareater level control

HP Heater 6 level control

HP Heater 7 level control

Hot well level control

Deareater pressure control

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Fuel Oil Supply Header Pressure Control ;-
Set Point Fuel Oil Supply Pressure
Control desk / OS After Heater
(0-40 kg/cm²)

(X)K

PI
Z/I
A /M

I /P

Fuel Oil Re-circulation Control Valve

NPTI
Boiler Drum Level Control ;-
Set Point
Drum Level
Control desk / OS (Compensated)

Feed Water Flow

- Steam Flow
k
Correction factor M 28% - Steam flow
A
Blow down X Zero
constant

(X)K (X)K

PI PI
Z/I Z/I
A /M A /M

I /P I /P

FCV 1 FCV 2

NPTI
Boiler Drum Level Control ;- Feedback

Set Point
Feed forward Drum Level
Control desk / OS (Compensated)
Cascade
Feed Water Flow
- Steam Flow
k
Correction factor M 28% - Steam flow
A
Blow down X Zero
constant

(X)K (X)K

PI PI
Z/I Z/I
A /M A /M

I /P I /P

Redundant
Redundant Final
FCV 1 controller
control element FCV 2

NPTI
LPH 3 LEVEL CONTROL;-

NPTI
LPH 3 LEVEL CONTROL;-
LPH3 level Set Point
(0-356 mmWc) (0-356 mmWc)

(X)K (X)K

PI
Z/I
os
Z/I A /M

I /P

LPH3 to LPH2
LPH3 to FT 0-50 %
50-100 %

NPTI
LPH 3 LEVEL CONTROL;-
LPH3 level Set Point
(0-356 mmWc) (0-356 mmWc)

(X)K (X)K

LPH2 level High

Protection close PI
Z/I
os
Z/I A /M

I /P

LPH3 to LPH2
LPH3 to FT 0-50 %
50-100 %

Split Range
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 HOTWELL LEVEL CONTROL;- Main condensate valve
CEP discharge to LPH
Recirculation valve
CEP discharge to Hotwell

100% open

0% close
0 30 100%
Hotwell Level

NPTI
HOTWELL LEVEL CONTROL;-

I/P
Hotwell

Recirculation valve
CEP discharge to Hotwell

Condensate Extraction Pump Main condensate valve

CEP discharge to LPH

NPTI
 HOTWELL LEVEL CONTROL;-
Hotwell level Set Point
(0-356 mmWc) (0-356 mmWc)

(X)K (X)K

PI
Z/I
os
Z/I A /M

I /P

Recirculation valve
Main condensate valve CEP discharge to Hotwell
CEP discharge to LPH

NPTI
Loop Consideration;-

Controller tuning
• Steady process / manual mode / No load change
• Vary proportional / Integral / Derivative gain
• Observe decay ratio / dead time / integral windup / Control deviation

Increasing Integral action causes CLCS more sensitive

Dead time leads to instability of loop response

Implement override control
(e.g, Scoop min 30%, LPH3- LPH2 level high protection close)

Include secondary measurements if necessary
(e.g., for MST flow compensation Pressure & Temperature also measured).

Different gain adjustment (e.g., during set point variation High / Low ramp)

Measurement / Control transmitters for high resolution
(e.g., Hotwell level 0-1600 mmWc / 0-356 mmWc)

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 The existence of a control loop does not always mean that the system is capable of
controlling to the degree required.
Concerns;-

Sensitivity and response time of the sensors and transducers.

Modes matching to application / controller (Dual loop for SH/RH temp control)

Tuning for specific condition

More Dead time (SH / RH attemperation control) & Hysteresis

Final control element size / shutoff / response / power to close against
differential pressure (e.g., DP in Feed water control valve)

Closed loop compatibility with control system

Criteria for evaluating good control;-

Stability of process

Minimum or no overshoot on startup

Minimum time to reach the desired set point

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 CO-ORDINATED MASTER CONTROL

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Mode of operation of the Unit;-

Turbine Follow Mode

Boiler Follow Mode

Co-ordinated Mode

Run Back Mode.

CMC comprises of;-

Fuel flow control

Combustion control

Throttle steam pressure control

Load on Turbo generator

Mode of operation logic

Load set point guidance including unit master

Run back load limit and generation

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Measurements for CMC;-

Fuel flow Measurements
 Plate Belt Feeder Speed
 Conveyor Belt Feeder Speed
 Furnace Oil Flow

Combustion air flow measurements
 Secondary air to all mills
 Hot air to all mills
 Hopper air
 Oil burner air flow

Steam Flow measurements

Feed water temperature measurement

Throttle steam pressure measurement

NPTI
Measurements for CMC;-

Fuel flow Measurements
 Plate Belt Feeder Speed
 Conveyor Belt Feeder Speed
 Furnace Oil Flow

Combustion air flow measurements
 Secondary air to all mills
 Hot air to all mills
 Hopper air
 Oil burner air flow

Steam Flow measurements

Feed water temperature measurement

Throttle steam pressure measurement

NPTI
 Co-ordinated Master Control;-
(211) Unit (199) Max (199) Unit
Capability Load limit Set point
(110) Min
Load limit

MIN

MAX

(-4MW/min) (-4MW/min)
Decreasing rate SPCM Increasing rate

(3.4MW) Frequency (199) Max (211) Unit

Influence Load limit Capability

RUN BACK
4ksc MIN #
k (150 ksc) Throttle
(623 t/hr)
steam flow
pressure SP BOILER
BFP
run back k (150 ksc) Throttle
FOLLOW MODE

pressure
Pressure SP to
Turbine (150ksc)

Pressure SP to HP B/P Boiler

Master

NPTI
 Co-ordinated Master Control;-

(739 t/hr)
Total air
(18.9MW) Frequency
Boiler Master flow
K Influence
X
SPCM (199MW) DELAY
(199) Max
MIN Load limit
(211) Unit
(201 t/hr) Capability
Total fuel
flow
MIN
Fuel Master

Pressure
correction

MILL A PBF1 Speed MILL C PBF1 Speed MILL F PBF1 Speed

MILL A PBF2 Speed
MILL B PBF1 Speed
MILL B PBF2 Speed MILL C PBF2 Speed …….... MILL F PBF2 Speed SP to
MILL A PBF3 Speed MILL B PBF3 Speed MILL C PBF3 Speed MILL F PBF3 Speed Turbine (199 MW)

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 Electro Hydraulic Governing / Controller

NPTI
 Electro Hydraulic Control System;-

Speed / Load / Pressure Control Loops

EH Controller Output

EH Converter

Change in Control Oil pressure

Turbine Valves;- Turbine Valves

Emergency stop valves

Governing valves (MSV /MCV / IPCV / IPSV)

Reheat stop valves

Interceptor control valves

Forced closed Non Return valves.

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 Load Control;-

After Synchronisation takes control

Selected during normal operation

Pressure corrected load set point

TSE influence

Speed Control Loop;-

Startup speed raising and synchronisation

Normal operation – Over speed controller

Takes control if other loops fails

TSE influence

Prevents over speed and restores in case of deviation

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 Pressure Control Loop;-

Two operating modes
 Limit Pressure Mode (Backup loop for Load Control Loop – Takes control if
Pr. Drops by 10 kg/cm²)
 Initial pressure Mode (Takes control of turbine directly)

LP Mode- Boiler Follows turbine (Load SP altered- load controller - changes -
steam flow rate - variation in the steam pressure  Boiler Master - adjusts - fuel and
air flow rate- changes in the fuel and air flow rate. back up loop. comes into action -
steam pressure gets reduced below set pressure by 10 Ksc and cannot be restored by the
combustion controller. )

IP mode – Turbine Follows Boiler (combustion - changes - steam pressure- MSP
maintained at set value - changes - closing/opening the governing valves - steam flow
rate - power generation.)

NPTI
THANK YOU

A presentation for NPTI, Neyveli

Sith.Ananda Kumar,
Assitant Executive Engineer,
Thermal Power Station-II,
Neyveli Lignite Corporation.
NPTI
NPTI
NPTI
NPTI
NPTI
Auxilliaries Unit capability Load

Mill (one) 76% 190MW

(two) 57% 142MW

BFP 48% 120MW

ID Fan 50% 126MW

FD Fan 50% 126MW

CWP 54% 135MW

Turbine Trip / Generator breaker open ---- -----

NPTI