CTCC Sabon 109FA – ICS Training

Control Loop

1- Prerequisites
a- PID
b- Water / Steam Curve
c- Instrumentation
2- HRSG
a- LP Eco
b- Drum Levels
c- FW Pumps
d- HP Steam Temp
e- HRH Steam Temp
f- Steam Bypasses
 CTCC Sabon 109FA – ICS Training

Control Loop

3- BOP
a- Condensate Pump
b- Condenser Level
c- Auxilliary Steam and
Cooling Steam
 CTCC Sabon 109FA – ICS Training

1- Prerequisites PID Control Setpoint = 50°C

a- PID

T=20°C T=35°C PID

Cold Water Hot Water

Control Valve

Gas Fuel
 CTCC Sabon 109FA – ICS Training

1- Prerequisites PID Control

a- PID Track Value Track Enable
Feedforward
Track Enable

P + +
Setpoint + Actuator
 I +
+
+
- D

PID Controller
Process
Variable
Process
 CTCC Sabon 109FA – ICS Training

1- Prerequisites
b- Water and Steam Curve
H2O – Saturation Curve
320°C

280°C

240°C

200°C
Temperature in °C

160°C

120°C

80°C

40°C

0°C
10 20 30 40 50 60 70 80 90 100 120

Pressure in Bara
 CTCC Sabon 109FA – ICS Training

1- Prerequisites Drum level Calculation

c- Instrumentation Water at Ambient temp

Water just bellow Tsat

PT
Steam just above Tsat

Level = f (p, P°)

Level
Range

p
 CTCC Sabon 109FA – ICS Training

1- Prerequisites
c- Instrumentation
Water and Steam Flow Calculation

PT TT p

Orifce plate creating a dP

Flow = f (p, P°, T°, design conditions)

 CTCC Sabon 109FA – ICS Training

2- HRSG
a- LP Eco
Water
To LP Drum
TT TT

dPmax

Setpoint = PV PID
LP Drum dP
Tsat – 5°C FT
PID

Setpoint =
Function of
Low Select Fuel Gas
Sulfur’s rate

PID TT

Water
From Condensate
 CTCC Sabon 109FA – ICS Training

2- HRSG
b- Drum Level
1 Element Control
PT

Water From Eco Steam To Superheater

Setpoint = Drum Drum Level

f(drum LT Calculation
pressure)
(during
startup) PID

Or PV
= 0 mm
(NWL)
Water Water and Steam
 CTCC Sabon 109FA – ICS Training

2- HRSG
b- Drum Level
3 Elements Control
PT

Water From Eco Steam To Superheater

FT
FT
Drum Drum Level
LT Calculation

PV
Bias
PID
PV PID Setpoint =
Setpoint f(drum
pressure)
Water Water and Steam
(during
startup)

Or

= 0 mm
(NWL)
 CTCC Sabon 109FA – ICS Training

2- HRSG
b- Drum Level Drum Level Start Up Curve

Pressure
 CTCC Sabon 109FA – ICS Training

2- HRSG IP FW Pumps
c- FW Pumps

IP Drum
LP Drum

PV
FT PID

Setpoint = 34 t/h
 CTCC Sabon 109FA – ICS Training

2- HRSG HP FW Pumps (Recirculation)

c- FW Pumps

HP Drum
LP Drum

FT

PT TT
PV PID
Hydrocoupling
Water Density
Flow Setpoint

F(x,y)
M RPM

Manufacturer Curve
 CTCC Sabon 109FA – ICS Training

2- HRSG HP FW Pumps (Speed)

c- FW Pumps

H L
dPT

HP Drum
LP Drum

PV
PID dP Setpoint = 16 Bar

Hydrocoupling Speed Command

M
 CTCC Sabon 109FA – ICS Training

2- HRSG
d- HP Steam Temp
Steam to HP ST Steam from HP
Superheater

TT

PV
Max Setpoint
PID
= 566 °C

Setpoint
PID PV
TT

Water from
HP FW Pump
 CTCC Sabon 109FA – ICS Training

2- HRSG
e- HRH Steam Temp
Steam to IP ST Steam from IP
Superheater

TT Steam from HP ST
Outlet

PV
Max Setpoint
PID
= 566 °C

Setpoint
PID PV
TT

Water from IP
FW Pump
 CTCC Sabon 109FA – ICS Training

2- HRSG
f- Steam Bypasses
PID Setpoint

PV

PT

Steam from
Superheater

TT

Water from
Condenser Condensate

PV
Setpoint PID

Attemperation with 1e control

 CTCC Sabon 109FA – ICS Training

2- HRSG Required
Water Flow
f- Steam Bypasses
Steam
Energy

Steam Flow
Caculation

PT TT

Steam from
Superheater

TT

Water from
Condenser Condensate
PV
Setpoint PV
Setpoint PID PID FT

Bias

Attemperation with 3e control

 CTCC Sabon 109FA – ICS Training

3- BOP
a- Condensate Pumps

Condenser

PV PID Setpoint :
1 or 2 pumps running

FT
To HRSG, Bypass
Attemperation …
 CTCC Sabon 109FA – ICS Training

Setpoint = 63 mm
3- BOP
b- Condenser Level Setpoint = 44 mm

PID PID

PV PV

LT

Condenser

Recirculation

To HRSG,
Bypass
Attemp …
 CTCC Sabon 109FA – ICS Training

3- BOP To Steam Seal

System
c- Auxiliary & Cooling Steam

Aux Steam from

Aux Boiler
SSFV SSDV

To drain system

Aux Steam from

IP Boiler
To LP Steam
Turbine
Low Select

PV
PID dPT
PID PV

Setpoint = Setpoint =
f(Condenser pressure) Required Steam
Flow (calculated)