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    Npti 20072010

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    Sai Swaroop
    This document discusses control loops in thermal power plants. It provides an overview of automation and the key elements of control loops, including controllers, measurements, final control elements, and the human-machine interface. Specific examples of control loops in steam generators and steam turbines are described in detail. These include drum level control, heater level controls, and hotwell level control. Tuning control loops and factors that affect control loop performance are also discussed.

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    Attribution Non-Commercial (BY-NC)
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    Npti 20072010

    Uploaded by

    Sai Swaroop
    256 views19 pages
    This document discusses control loops in thermal power plants. It provides an overview of automation and the key elements of control loops, including controllers, measurements, final control elements, and the human-machine interface. Specific examples of control loops in steam generators and steam turbines are described in detail. These include drum level control, heater level controls, and hotwell level control. Tuning control loops and factors that affect control loop performance are also discussed.

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    This document discusses control loops in thermal power plants. It provides an overview of automation and the key elements of control loops, including controllers, measurements, final control elements, and the human-machine interface. Specific examples of control loops in steam generators and steam turbines are described in detail. These include drum level control, heater level controls, and hotwell level control. Tuning control loops and factors that affect control loop performance are also discussed.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    256 views19 pages

    Npti 20072010

    Uploaded by

    Sai Swaroop
    This document discusses control loops in thermal power plants. It provides an overview of automation and the key elements of control loops, including controllers, measurements, final control elements, and the human-machine interface. Specific examples of control loops in steam generators and steam turbines are described in detail. These include drum level control, heater level controls, and hotwell level control. Tuning control loops and factors that affect control loop performance are also discussed.

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    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

    Control loop
    Auto / Manual Closed / Open Critical / Non-Critical Local / Remote

    NPTI 20072010

    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
    NPTI 20072010

    Elements of Control Loop


    Process Measurement System Final Control Element Human Machine Interface Controller / Program
    Process Controller (Decision) Measurement (Process Variable)

    Action (Final Control Element)

    Necessity for Control Loop


    For Optimal operation of process within range Sequential execution cannot be applied always Quick response / High sensitivity

    NPTI 20072010

    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 20072010

    Desk Control Tiles;HPH6 to DEA / LPH4 2LCV553_063


    -20 0 +20
    50 100 % 50 0 0 100 +20

    -20

    10
    0

    %
    100

    VALVE POSITION

    COMMAND / DEV

    48.15 168 PV
    M CLS A/M

    % 175 SP
    A OPN

    +50

    -50

    mmWc AUTO / MAN

    SET POINT

    NPTI 20072010

    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.)
    NPTI 20072010

    Control Loops Steam Generator


    Furnace draft control Secondary air header pressure control Superheated steam temperature control Reheated steam temperature control

    Fuel oil supply header pressure control


    Fuel oil temperature control Fuel oil flow control Atomising steam header pressure control Secondary air flow to oil burner control Hopper air flow control Mill outlet temperature control

    Load and combustion control


    Auxiliary steam pressure control Auxiliary steam temperature control

    Feedwater flow control


    Air heater average cold end temperature control

    NPTI 20072010

    Control Loops Steam Turbine


    BFP Scoop Control LP Heater 1 level control LP Heater 2 level control LP Heater 3 level control LP Heater 4 level control BFP recirculation control CEP minimum recirculation flow control MST to Ejector pressure control BFP Seal water temperature control Gland steam pressure control Gland steam temperature 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

    NPTI 20072010

    Boiler Drum Level Control ;Set Point


    Control desk / OS

    Drum Level
    (Compensated)

    Feed Water Flow - Steam Flow


    Blow down constant

    k
    Correction factor

    M A X

    28% - Steam flow Zero

    (X)K
    PI A /M PI

    (X)K

    Z/I

    A /M

    Z/I

    I /P

    I /P

    FCV 1

    FCV 2

    NPTI 20072010

    Boiler Drum Level Control ;Feed forward


    Set Point
    Control desk / OS

    Feedback

    Drum Level
    (Compensated)

    Cascade
    Feed Water Flow - Steam Flow
    Blow down constant

    k
    Correction factor

    M A X

    28% - Steam flow


    Zero

    (X)K
    PI A /M PI

    (X)K

    Z/I

    A /M

    Z/I

    I /P

    I /P

    FCV 1

    Redundant Redundant Final controller control element

    FCV 2

    NPTI 20072010

    LPH 3 LEVEL CONTROL;-

    NPTI 20072010

    LPH 3 LEVEL CONTROL;LPH3 level


    (0-356 mmWc)

    Set Point
    (0-356 mmWc)

    (X)K

    (X)K

    PI

    os
    Z/I
    A /M

    Z/I

    I /P

    LPH3 to FT
    50-100 %

    LPH3 to LPH2
    0-50 %

    NPTI 20072010

    LPH 3 LEVEL CONTROL;LPH3 level


    (0-356 mmWc)

    Set Point
    (0-356 mmWc)

    (X)K

    (X)K

    LPH2 level High Protection close Z/I

    PI

    os
    A /M

    Z/I

    I /P

    LPH3 to FT
    50-100 %

    LPH3 to LPH2
    0-50 %

    NPTI 20072010

    HOTWELL LEVEL CONTROL;Recirculation valve CEP discharge to Hotwell

    Main condensate valve CEP discharge to LPH

    V a l v e
    p o s i t i o n

    100% open

    0% close

    30

    100%

    Hotwell Level

    NPTI 20072010

    HOTWELL LEVEL CONTROL;I/P Recirculation valve CEP discharge to Hotwell

    Hotwell

    Condensate Extraction Pump

    Main condensate valve CEP discharge to LPH

    NPTI 20072010

    HOTWELL LEVEL CONTROL;Hotwell level


    (0-356 mmWc)

    Set Point
    (0-356 mmWc)

    (X)K

    (X)K

    LPH2 level High Protection close Z/I

    PI

    os
    A /M

    Z/I

    I /P

    Main condensate valve


    CEP discharge to LPH

    Recirculation valve CEP discharge to Hotwell

    NPTI 20072010

    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)

    NPTI 20072010

    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
    NPTI 20072010

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