KEPCO Research Institute

OGS – Operator Guided Simulator

Control circuits and their response

– shown at the simulated CCPP
Sloe Central / Netherlands
 Training Scope

The scope of the training is to demonstrate and analyze different types of

controls during operation of a real time simulated CCPP.
The aim for the trainees is to understand the task and the design of
these controls including analyzing of the control quality via trend
function.
Therefore the controllers will be discussed via HMI, related function
charts and self prepared / modified diagrams before, during and after
activating of set point or process status changes.
Plant Constellation

Power plant features of Sloe Central / Netherlands:

• constellation : two single shaft units
• gasturbine: SGT5-4000F (6)
• steam turbine: SST5-5000 (KN)
• HRSG: three pressure stages
- high pressure benson type
- intermediate and low pressure drum type
• cooling type: once through, sea water (high tide hub)
• special feature: process steam via cold reheat
• plant output / power: 870 MW (2 x 435 MW)
 Plant Overview

LP superheater
Auxiliary boiler

HAD10
HAD50
LP evaporator reheater process steam GHC
HAD80
LP LAA
LBG M MBL70
MAW
IP superheater
Deionat
tank
IP evaporator
IP LP bypass station
HP bypass station
LBG
M
HP superheater IP bypass station

HP evaporator LBG make up water

LBG
HP economizer
M

IP economizer

M
M
LBG
M
LDK

GT intake air preheating

M

feed water pumps condensate preheater main condensate pumps

system
fuel gas preheating
 Content of discussed Controls

• Condenser Level Control

• Condensate Preheater Inlet Temperature Control (Sulfur Dew Point)
• IP Drum Level Control
• Main Steam temperature Control upstream Steam Turbine
• Enthalpy Control of HP Benson Type Boiler
Condenser Level Control Slow process

Demin water supply

for level control

level to be
controlled
 Condenser Level Control Slow process

GHC
FL calculated limit

M
CL CL CL

- Simplest control (two point control)

- large lag time due to condenser hotwell volume
- make up capacity design for normal water losses during operation
Condenser Level Control Slow process
Start with screen shot : 20110727_113024_350MW_KEPRI
Increase of water losses at simulator (downstream LCB’s)

setpoint change

target value
reached

required values
Condensate Preheater Inlet Temperature Control Slow process

adjustable condensate
recirculation via
preheater inlet
additional pumps
temperature setpoint as
cold bypass function of sulfur content
at fuel (natural gas)

recirculation via
feedwater pumps

temperature to
be controlled

step matrix for

controller activation
 Condensate Preheater Inlet Temperature Control Slow process

- indirect control of flue gas

temperature (sulfur dew point)
via condensate preheater inlet
temperature
- slow control due to lag time of
heat transfer
 Condensate Preheater Inlet Temperature Control Slow process
Start with screen shot : 20110727_113024_350MW_KEPRI
Setpoint of sulfur content at fuel change to 90mg/Nm³ corresponding to inlet temperature of 96,4°C

CPH inlet temperature

Step 02 – start CPH recirculation

Step 01 – increasing of feedwater recirculation Step 06 – opening cold bypass

 Condensate Preheater Inlet Temperature Control Slow process
Start with screen shot : 20110727_113024_350MW_KEPRI
Setpoint of sulfur content at fuel change to 90mg/Nm³ corresponding to inlet temperature of 96,4°C
pressure increase lp-steam / HRSG system

lp steam pressure

Step 03 > 4,8 bar Step 04 > 5,8 bar Step 05 > 6,8 bar

start closing lp-turbine CV

 IP Drum level Control fast process

ip boiler feedwater control

valve (level control)
level to be
controlled

ip boiler drum
overflow control valve
 IP Drum level Control fast process

IP drum level set

points and attached
subloop controls
 IP Drum level Control fast process

- different start up and operation set points for drum level

- during operation so called „three point control“ / risk of evaporator volume collapse due to feedwater supply
- influence of pressure changes by steam turbine and steam bypass control
 IP Drum level Control during cold start of CCPP fast process
Start with screen shot : 20110111_104829_CJA25_bef_SGC_HAD80
SGC manual related stop of CJA sequence – reset of SGC’s required
opening of ip GT flame ON
boiler feedwater
isolation valves

drum filling to
overflow setpoint start up level
drum level drum wall
temperature

level setpoint

fill flow active

ip feedwater flow
 IP Drum level Control during cold start of CCPP fast process
Start with screen shot : 20110111_104829_CJA25_bef_SGC_HAD80
SGC manual related stop of CJA sequence – reset of SGC’s required
overflow first evaporation – drum wall
setpoint drum wall temperature
temperature >105°C

unit in boiler soaking

/ waiting for first
evaporation feed ctrl
drum valve
level position
level setpoint

level tracking active

fill flow active Filling and start of
fuel gas preheating

steam flow >

ip feedwater eco min flow
flow
 HP Steam Temperature Control upstream Steam Turbine fast process

interstage
temperature to
desuperheater is be controlled
supporting the final
desuperheater
(influence to
efficiency and ASME)
final desuperheater for max.
hp steam temperature control
upstream steam turbine

interstage
desuperheater for
max. hp steam
superheater outlet
temperature control
HP Steam Temperature Control upstream Steam Turbine fast process

- LAE11 – increase of heat transfer due to high dT but exergy losses for hp evaporator
- LAE20 – risk of water droplets upstream of steam turbine (ASME; additional drains required)
 HP Steam Temperature Control upstream Steam Turbine fast process
Start with screen shot : 20110727_113024_350MW_KEPRI
Setpoint of LBA10DT002 / 216016 change from 566°C to 530°
fast process

delayed setpoint
decrease (setpoint steam temperatures
change) downstream LAE20

opening of steam temperatures

interstage downstream LAE11

opening of final
HP Evaporator Enthalpy Control slow process

superheated to
be controlled
enthalpy set point

hp boiler feedwater control

valves (level control)
HP Evaporator Enthalpy Control slow process

feedwater pump
speed control
HP Evaporator Enthalpy Control slow process

- enthalpy control only for BENSON operation

- fast controlling components with large lag time due to boiler heat storage capacity
 HP Evaporator Enthalpy Control slow process
Start with screen shot : 20110727_113024_350MW_KEPRI