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DEAERATOR PRESSURE CONTROL DEAERATOR LEVEL CONTROL CEP RECIRCULATION CONTROL HOT WELL LEVEL CONTROL SCAPH TEMP. CONTROL BFP RECIRCULATION CONTROL HP HEATER 5&6 LEVEL CONTROL LP HEATER 2&3 LEVEL CONTROL
: : : : : : : :
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ABB
Depending upon the unit loading , the operation of the Deaerator pegging can be divided in three parts as under : 1. Normal Operation 2. Operation on Turbine Trip with Boiler survived 3. Operation on Turbine Trip with Boiler also tripped
1)
NORMAL OPERATION :
During starting / low load or turbine bypass operation of the Unit, Deaerator is pegged with Aux. Steam, when CRH pressure is less than 4 Kg/cm2. The set value is a max. selection of operator adjustable fixed set point or 1.5 Kg/cm2 preset value. The set value is compared with Deaerator pressure and the error signal is applied to PI controller whose output acts upon a aux. Steam control valve. When CRH Steam Pr. is more than 8 Kg/cm2, the control of Deaerator Pr. is switched over to CRH Steam Control Valve, and Aux. Steam Control Valve is gradually closed to min. The effective set point of 3.5 Kg/cm2 acts on PI controller whose output modulates the CRH steam control valve during bypass, warm and hot start up operation. When the load rises to more than about 45 % of the full load, the turbine extraction steam pressure exceeds 3.5 ata and the NRVs in the extraction line allows extraction of steam to the Deaerator, thereby raising the Deaerator Pressure further and beyond 3.5 ata ( as per extraction steam pressure ). The CRH steam supply valve is then closed down automatically, as the prevailing Deaerator pressure is more than the set point to its controller. When ever extraction steam pressure is less than 3.5 ata because of load rejection or HP / LP Bypass operation, the CRH steam supply valve controller maintains the Deaerator pressure at 3.5 ata . In case of sudden load rejection, the pressure in Deaerator may reduce at a faster rate than is permissible and may cause serious damage to the equipment.
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ABB
To arrest the pressure decay rate under such circumstances, a variable / sliding set point is generated from the actual Deaerator pressure signal reduced by 0.5 ata through controlled tracking integrator GNI.
Set Point Deaerator Pressure 1.5 Kg/cm2 MAX + -dy SE CRH Pr. > 8 Kg/cm2 & I CRH Pr.<4 Kg/cm2 Low Load By Pass in operation
PI+P
Auto
The GNI output slides down at a rate not more than 0.5 ata per min. The biased and sliding set point is compared with the min. pegging pressure of 3.5 ata in maximum selector, and greater of the two is given as set point to CRH steam valve controller with PI control structure. Hence, in case of sudden load rejection, when pressure of turbine extraction steam falls at a steep rate, the pressure decay rate in the Deaerator is arrested to not more than 0.5 ata per min. by steam supply from CRH steam line.
2)
Under the circumstances , when the turbine has tripped and the boiler has been survived through automatic / manual opening of HP / LP Bypass Valves and with proportionate reduction of Fuel & Air input to Boiler; the control of Deaerator Pr. is taken over by CRH Steam Control Valve with sliding operation similar to that as explained above for sudden load rejection. A controlled tracking integrator (GNI) tracks the actual Deaerator pressure less by 0.5 Kg/cm2. The output of the tracking integrator slides down at the rate not more than 0.5 Kg/ min. and is compared with the operator adjusted manual set point in a minimum selector. The output of the min. selector or a preset value of 3.5 Kg/cm2,
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ABB
whichever is more is passed on to the controller as set value and is compared with the Deaerator pressure for the control of CRH steam control valve. Deaerator Pressure 0.5 Kg/cm2 Gd = 0.5 Kg/min. Turbine Tripped + Set Point
GNI
3.5 Kg/cm2 MIN MAX + -dy SE I CRH Pr.<4 Kg/cm2 Extrn. Pr.>min. & Bypass not in operation
CRH Pr.>8 Kg/cm2 Low Load Hot start I Warm start Bypass in operation
Auto & I
PI+P
3)
Under the circumstances when Boiler is also tripped on tripping of the Turbine, the control of Deaerator Pressure is switched over to Aux. Steam Control Valve, as there will not be any steam in CRH line.
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ABB
Total FW Flow
Set Point
Deaerator Level
PI+P
PI+P
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ABB
The minimum condensate flow through gland steam condenser specially during start up and low load condition is controlled by regulating the flow control valve in CEP Re-circulation line to condenser. The measured condensate flow at the outlet of gland steam condenser is compared with a manually set desired value and the error signal is applied to a PI controller , the output of which modulates the recirculation valve, so as to maintain the condensate flow through gland steam condenser above the desired set value .
Set Point
Condensate Flow
PI+P
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ABB
Measured value of Hot Well level is compared with a manually set low level desired value, the error signal is applied to a PI controller, the output of which modulates an emergency make up water control valve .
b)
Measured value of Hot Well level is compared with a manually set high level desired value, the error signal is applied to a PI controller, the output of which modulates condensate spill valve, so as to regulate condensate spill to condensate surge tank.
PI+P
PI+P
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ABB
PI+P
PI+P
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ABB
SET VALUE
PI
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ABB
A)
The condensate level of HP Heater-6 is controlled by modulating the following three control valves : 1. Normal Low Level control to HP Heater-5 2. Normal High Level control to Deaerator and 3. Emergency Very High Level control to Condenser . Three separate control loops are envisaged for the purpose. The measured HP Heater-6 level is compared with the manually set desired value. The error signal is applied to a PI controller, whose output modulates the respective drain control valves. The set points are selected in such away so as to avoid interaction among these controllers. Extraction Steam Normal Normal Emergency Low High Very High Level Level Level HP HTR-6 FEED WATER FROM HPH-5
PI
PI
PI
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ABB
B)
The condensate level in HP Heater-5 is controlled by modulating the following two drain control valves : 1. Normal Level control to Deaerator, and 2. Emergency Very High Level control to Condenser. Two separate control loops are envisaged for the purpose. The measured HP Heater-5 level is compared with the manually set desired value. The error signal is applied to a PI controller, whose output modulates the respective drain control valves. The set points are selected in such away so as to avoid interaction among these controllers. Extraction Steam Normal Level HP HTR-5 FEED WATER FROM BFP Emergency Very High Level
PI
PI
TO DEAERATOR TO CONDENSER
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ABB
The condensate level in LP Heater-3 is controlled by modulating the following two drain control valves : 1. Normal Level control to LP HEATER-2, and 2. Emergency Very High Level control to Condenser. Two separate control loops are envisaged for the purpose. The measured LP Heater-3 level is compared with the manually set desired value. The error signal is applied to a PI controller, whose output modulates the respective drain control valves. The set points are selected in such away so as to avoid interaction among these controllers. Extraction Steam Normal Level LP HTR-3 CONDENSATE FROM LPH-2 Emergency Very High Level
PI
PI
TO LP HTR-2 TO CONDENSER
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ABB
B)
The condensate level in LP Heater-2 is controlled by modulating the following two drain control valves : 1. Normal Level control to LP HEATER-1, and 2. Emergency Very High Level control to Condenser. Two separate control loops are envisaged for the purpose. The measured LP Heater-2 level is compared with the manually set desired value. The error signal is applied to a PI controller, whose output modulates the respective drain control valves. The set points are selected in such away so as to avoid interaction among these controllers. Extraction Steam Normal Level LP HTR-2 CONDENSATE FROM LPH-1 Emergency Very High Level
PI
PI
TO LP HTR-1 TO CONDENSER
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