BANG

PAKONG

3/4

MODULATING

OPERATING

CONTROLS

PROCEDURES

CONTENTS

CONTENTS.INS 210392

UNIT MASTER

AIR FLOW

FLUE GAS 02 AND CO CONCENTRATION

GAS FUEL FLOW

OIL FUEL FLOW

GOVERNOR POSITION

FURNACE PRESSURE - ID FAN DAMPERS

ID FAN SPEED

DRUM LEVEL - MOTOR BOILER FEED PUMPS

10

DRUM LEVEL - TURBINE BOILER FEED PUMPS

11

DEAERATOR LEVEL - CONDENSATE PUMPS

12

CONDENSER LEVEL

13

SECONDARY SUPERHEATER OUTLET TEMPERATURES

14

TERTIARY [FINAL] SUPERHTR OUTLET TEMPERATURES

15

REHEAT STEAM TEMPERATURE [GAS RECIRC]

16

REHEAT STEAM TEMPERATURE [SPRAYS]

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
UNIT

:1

CONTROLS

MASTER
MASTER.INS 030992

-------------------------------------------------------------------SYSTEM

BOILER-TURBINE COORDINATION

CON.T VARIABLE

MEGAWATTS, PRESSURE

CONTROL DEVICE

GOVERNOR, FUEL AND AIR SUBLOOPS

SET VALUE

REQUIRED UNIT OUTPUT AND PRESSURE

GSM PB

"UNIT MSTR"

GROUP DISPLAY

001

UNIT MASTER

TX DEVN DISPLAY

089

MASTER

(A)

& AIR XMTRS

PERMISSIVES

(1)

Coordinated Mode: Air Flow, Fuel Flow, Governor, Main Steam Temperature,
Feedwater Flow and Condensate Flow controls selected to AUTO.

(2)

Boiler Follow Mode: Air Flow, Fuel Flow and Governor (optional) selected
to AUTO.

(3)

Base Input Mode: Air Flow, Fuel Flow and Governor (optional) selected to
AUTO.

(4)

Manual Mode: None.

(B)

[Air flow may be on AUTO].

OPERATOR

ACTION
relevant Operating

Pre-select required subloops to

Procedure].

(2)

Select Group
subwindows.

(3)

Select the required mode. The subwindow displays the selected mode. If
the required permissives are not complete, "PERMISSIVE LOSS" will be
indicated. Any faulty transmitter affecting the Unit Master or Fuel/Air
Deviation condition will force the Unit Master to remain in Manual Mode.

(4)

After about 5 seconds the mode selection subwindow indicates the mode
active condition. If the system remains in the mode selected status it
means that one of the subloops is not correctly initialized [balanced].
This can be caused by excessive air flow, significant change in fuel
heating value or faulty transmitter calibration.

Operation

Display

AUTO.

[Refer to

(1)

001

["UNIT

MSTR"]

and

ENABLE

all

-2(5)

The Pressure Set Point initializes at the existing pressure.

The
pressure may be set to the desired value after auto operation achieved.
Alternatively, select sliding pressure by selecting AUTO on the
pressure set point subwindow.
Sliding pressure is available in
Coordinated Mode or Boiler Follow Mode with Governor AUTO.

(6)

The Target Load Set Point initializes at the existing MW for CO and BF
Modes and at Fuel Flow for BI Mode.
Set the desired MW load at the
Target Load Set Point Subwindow.

(7)

Set the
facility
System
burners

(8)

Set the required load change rate in MW/MIN at the Rate subwindow.
Then select AUTO at this subwindow to permit the load change to start.

(9)

If ADS control of the Target Load is required, select AUTO on the Target
Load subwindow. ADS control is available in the CO Mode only.

(C)
(1)

Minimum and Maximum Load at the appropriate subwindows. This

is mainly to limit the load range under Automatic Dispatch
[ADS] control.
The setting is determined by the number of
in service and any other operational constraints.

COMMENTS
The maximum load is limited by the auxiliary plant capacity.
[PID:
This is calculated from the number of Fans, Feedpumps,
COAW408]
Condensate Pumps and Boiler Circulating Water Pumps in service as
follows:
Each FD Fan
Each ID Fan
Each MDBFP
Each TDBFP
Each Cond Pump
Two BCWP
Three BCWP

360
360
90
360
350
360
600

MW
MW
MW
MW
MW
MW
MW

The lowest value from the four auxiliary groups is selected; for
example, one TDBFP and one MDBFP would limit the target load to 450 MW.
The maximum value of Auxiliary Plant Capacity [APC] is 635 MW.
(2)

The Required Output [COAY400] is calculated from the Target Load, Rate
Setter, Minimum and Maximum Limits .and the Auxiliary Plant Capacity.
The Required Output [RO] is the set point for Governor, Fuel and Air
control loops.

(3)

I f an auxiliary trip causes the APC to drop below the existing RO, a
RUNBACK is initiated. This causes the RO to decrease as a fast rate to
the new value determined by the APC. The Unit Master is automatically
transferred to BI Mode before the Runback starts.

(4)

The major flow loops are checked for abnormal deviation from th~
required value.
This applies to Fuel, Air, Governor, Feedwater and
Condensate. I f the auxiliary plant is unable to follow the load demand
for any reason, a flow deviation occurs.
For example, fuel valve at
maximum causes a fuel flow low condition.
Any increase in RO is
blocked and, after a short time delay, the RO is reduced until the
deviation is within limits.

-3-

(5)

Modes:
MANUAL
The target load and required output tracks fuel flow.
The Air Flow and Oxygen controls may be placed on AUTO.
The Air
Demand follows Fuel Flow when above the minimum air flow limit. Manual
Mode is normally used at unit start up until stable firing conditions
are achieved.
BASE INPUT
The boiler energy input [fuel and air] is set by the
Target Load.
The resulting MW depends on the fuel heating value.
Pressure is controlled to a fixed set point if the Governor is on AUTO
[Turbine Follow].
If the governor is not auto, the pressure is
proportional to firing rate and inversely proportional to governor
position. Changes in governor position causes transient change to MW.
Base Input Mode is used when stable boiler operation is required.
BOILER FOLLOW
The boiler input is determined by the turbine energy
demand. This is calculated from First Stage Pressure, Throttle Pressure
and Pressure Set Point. Pressure correction is made by adjusting t
boiler inputs [fuel and air].
The governor may be on automatic c..
manual operation.
If the governor is on AUTO it controls MW at the
Target Load setting [para (2)] and sliding pressure is permitted.
The
Boiler Follow Mode allows responsive control when the governor is not
available for automatic operation.
COORDINATED
The boiler inputs [fuel and air] and the governor
respond to a common demand signal, Required Output.
Refer to
Paragraph (2).
Sliding pressure and ADS control is available in this
mode. The governor is adjusted to control MW and the boiler inputs are
regulated to maintain pressure.
The Coordinated Mode is the normal
method of operation.

BANG

CONTROLS

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
2

COMBUSTION

AIR

FLOW
AIRFLOW.INS 030992

-------------------------------------------------------------------SYSTEM

COMBUSTION AIR

CONT VARIABLE

TOTAL COMBUSTION AIR FLOW

PID :

CONTROL DEVICE

FD FAN BLADE PITCH ANGLE

3SGB-CDR-1,2

SET VALUE

CALCULATED BY BOILER MASTER

GSM PB

"COMB AIR"

GROUP DISPLAY

002

COMBUSTION AIR

TX DEVN DISPLAY

089

MASTER

(A)

& AIR XMTRS

PERMISSIVES:

(1)

Fan selected for auto operation ON [running).

(2)

Pitch control oil pressure > 28 Bar.

(3}

No Fuel/Air Transmitter deviation.

(4)

One or both ID fan damper AUTO.

(B)

SGBF409

OPERATOR

ACTION:

(1)

Select group operation display 002

subwindows for FD fans blade pitch.

[GSM

"COMB

AIR")

and

ENABLE

the

(2)

Check that the indicated Air Demand [SV] is a reasonable value for the
existing load condition.
[e.g. for 300MW, should be approximately 50%.
The minimum is 33%]
The PV and SV indications on Fan lA subwindow
should be aligned, indicating tracking' balance.

(3)

Set bias setting on Fan lA to zero [centre-scale).

(4)

Select AUTO for fans in service.

(5)

Adjust bias setter if required.

-2-

(C)

COMMENTS:

(1)

The basic Air Demand equals the Required Output [RO] calculated by the
Boiler Master.
When the Boiler Master is in MAN mode, the RO equals
Fuel Flow.

(2)

The excess air is calculated from the .RO and the 02 set point.
The
excess air component is added to the basic [stochiometric] air demand.
Refer to 02 control notes.

(3)

Air flow control should be selected to auto before light-off; this

ensures that the flow is maintained above the minimum air flow required
for purge. [The minimum air flow is set at 33% ECR flow.]

(4)

Boiler Trip [MFT] trips air flow to manual.

minute.

(5)

After selecting Air Auto, AUTO will be indicated on the subwindow if t'
permissives are OK.
The MAN indication will remain on until boile1
master permissives and initialization check is complete [WAITING]. This
takes about 5 seconds. If MAN remains on, air flow may be excessive
for firing rate, or boiler master permissives not complete, or ID fan
damper Not Auto. If air flow is excessive, the PV and SV arrows on Fan
lA subwindow will not align and the flue gas 02 indication will be
higher than the set point. Reduce air flow until tracking balance is
achieved.

(6)

Pitch oil pressure low [<12 Bar] or excess furnace pressure deviation
blocks both AUTO and MANUAL operation of blade pitch.

It may be reset after one

BANG
3

PAKONG 3 / 4 MODULATING CONTROLS

OPERATING PROCEDURE

FLUE

GAS

&

OXYGEN

CARBON

MONOXIDE
02ANDCO.INS 030992

-------------------------------------------------------------------SYSTEM

COMBUSTION AIR

CONl' VARIABLE

FLUE GAS 02 & CO CONCENTRATION

CONTROL DEVICE

EXCESS AIR DEMAND

SET VALUE

CALCULATED BY AIR FLOW CONTROL

GSM PB

"COMB AIR"

GROUP DISPLAY

002

COMBUSTION AIR

TX DEVN DISPLAY

089

MASTER

& AIR XMTRS

PERMISSIVES

(A)

Flue Gas 02
(1)

No 02 transmitter deviation.

(2)

Air Flow Contol selected to AUTO.

(3)

Air Flow greater than minimum flow [33% ECR].

Flue Gas

[Monitor ON.]

co

(1)

No CO transmitter deviation.

(2)

02 control AUTO.

OPERATOR

(B)

[Monitor ON.]

ACTION

Flue Gas 02
If all

(1)

Check 02 transmitters [ 4] for reasonable value.

[Display 089].
OK, select Transmitter 1 for East and West sides with monitor ON.

(2)

Select group operation display 002 [Combustion Air] and ENABLE

subwindows 3 and 4.
With CO control in MAN, set output [MV] of CO
subwindow to zero. [Centre-scale.]

(3)

Check 02 set value on subwindow 3 SV. This is calculated

load.
If a different value is required, manually adjust
output MV [subwindow 4] to obtain the desired set value
control subwindow SV. The range of adjustment is limited to

(4)

Select AUTO on 02 subwindow.

from boiler
CO control
on the OZ
+/- 2% 02.

-2Flue Gas CO
(1)

Check CO transmitters for reasonable value.

select transmitter 1 with monitor ON.

(2)

Select group operation display 002 [Combustion Air} and

subwindow 4. Adjust the set value SV to the required value.

(3)

Select AUTO on CO subwindow.

(C)

[Display 089].

If both OK,

enable

COMMENTS

(1)

Manual adjustment of excess air is made from the 02 subwindow MV in

MAN mode. The 02 MV can only be adjusted when combustion air control
[FD fans] is in AUTO mode.

(2)

When 02 control is suspended because the air flow is at m~n~mum, both

AUTO and MAN indications show on the 02 subwindow [WAITING].

(3)

The real time trend for air flow, fuel flow, 02 and CO should be checked
frequently for normal combustion conditions.

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
4

GAS

FUEL

CONTROLS

FLOW
GASFUEL.INS 030992

SYSTEM

GAS FUEL

CONT VARIABLE

GAS FUEL FLOW

FGAF408

CONTROL DEVICE

CONTROL VALVES

3FGA-ACV-l,

SET VALUE

CALCULATED BY BOILER MASTER

GSM PB

"FUEL"

GROUP DISPLAY

004

FUEL

TX DEVN DISPLAY

090

FUEL FLOW XMTRS

(A)

PERMISSIVES:

(1)

Any burner level selected for GAS firing.

(2)

Trip Valve open; header pressure

(3)

No Fuel/Air transmitter deviation.

(4)

No Heat Release/Metered Fuel Flow deviation.

(5)

Fuel/Air Ratio normal.

(6)

M.F.T. reset.

(7)

Combustion Air selected to AUTO.

(8)

Boiler Master Mode selected [CO, BF or BI].

>

0.11 Bar.

-2( B1)

OPERATOR

ACTION

[GAS

ONLY

FIRING]

(1)

Select Group Operation Display 004 (FUEL) and ENABLE subwindow of the
fuel gas control valve required for auto operation.
The capacity of
each gas control valve is about 60% ECR. At higher loads with gas fuel
only, two valves are required on Auto ..

(2)

Check gas fuel flow PV is reasonable

condition. Note that SV tracks fuel.

(3)

Select AUTO for the required valve.

(4)

Note AUTO indication on; at this stage MANUAL indication

[WAITING]. If no AUTO, check permissives (A) and tracking.

(5)

Select BOILER MASTER Group Operation Display 001.

(6)

Select Governor mode [Auto/Manual], Coordinated Control mode [BI, BF o

CO]. and Pressure mode [Sliding/Fixed], {Refer to separate procedure fc
Boiler Master.}

(7)

value

for

the

existing

also

load

on

After initialization and balance check [5 seconds], the selected boiler

mode becomes active and the fuel, (as well as air and governor)
_..........-go to Jtuto Mode. The subwindow MANUAL indication is now off.
mast~

( B2)

COMBINED

FIRING

(1)

Refer to Fuel Oil Operating Procedure for permissives for Oil firing.

(2)

If AUTO operation of oil fuel required, select required oil valve to

AUTO.

(3)

Set Oil Ratio Setter to required percentage oil flow.

[The Oil Ratio
Setter tracks the percentage oil fuel if BOTH fuels are NOT auto.]

(C)
(1)

COMMENTS:
Gas fuel flow control functions between burner header pressure limits
0.15 to 1.50 Bar.
If a limit is reached, the fuel gas flow control
transfers to header pressure control. An alarm is initiated to advise
"Gas Limited" condition exists.
If oil is on auto, the gas error is
transferred to the oil control.

/
! '

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
5

OIL

FUEL

CONTROLS

FLOW
OILFUEL.INS 030992

SYSTEM

OIL FUEL

CONT VARIABLE

OIL FUEL FLOW

FOBF407

CONTROL DEVICE

CONTROL VALVES

3FOB-ACV-7,8

SET VALUE

CALCULATED BY BOILER MASTER

GSM PB

11

GROUP DISPLAY

004

FUEL

TX DEVN DISPLAY

090

FUEL FLOW XMTRS

(A)

I I

FUEL 11

PERMISSIVES:

(1)

Any burner level selected for oil firing.

(2)

Trip Valve open; header pressure

(3)

No Fuel/Air transmitter deviation.

(4)

No Heat Release/Metered Fuel Flow deviation.

(5)

Fuel/Air Ratio normal.

(6)

M.F.T. reset.

(7)

Combustion Air selected to AUTO.

(8)

Boiler Master Mode selected [CO, BF or BI].

>

6.5 Bar.

-2( B::l)

ACTION

[OIL

ONLY

FIRING]

(1)

Select Group Operation Display 004 (FUEL) and ENABLE subwindow of the
fuel oil control valve required for auto operation. [Only ONE valve of
pair ACV-7/ACV-8 permitted on auto at same time; each valve is >100%
capacity].

(2)

Check fuel flow PV is reasonable value for the existing load condition.
Note that SV tracks fuel.

(3)

Select AUTO for the required valve.

(4)

Note AUTO indication on; at this stage MANUAL indication

[WAITING] I f no AUTO, check permissives (A) and tracking.

(5)

Select BOILER MASTER Group Operation Display 001.

(6)

Select Governor mode [Auto/Manual], Coordinated Control mode [BI, BF or

CO] and Pressure mode [Sliding/Fixed]. {Refer to separate procedure f
Boiler Master.}

(7)

After initialization and balance check [5 seconds], the selected boiler

master mode becomes active and the fuel, (as well as air and governor)
go to Auto Mode. The subwindow MANUAL indication is now off.

( B2)

COMBINED

also

on.

FIRING

(1)

Refer to Fuel Gas Operating Procedure for permissives for Gas firing.

(2)

If AUTO operation of gas fuel required, select required gas valve to

AUTO.

(3)

Set Oil Ratio Setter to required percentage oil flow.

[The Oil Ratio
Setter tracks the percentage oil fuel if BOTH fuels are NOT auto.]

(C)

I l..

OPERATOR

COMMENTS:

(1)

Oil fuel flow control functions between burner header pressure limits
7.5 to 21.0 Bar.
If a limit is reached, the fuel oil flow control
transfers to pressure control.
An . alarm is initiated to advise "Oil
Limited" condition exists.
If gas is on auto, the oil error is
transferred to the gas control.

(2)

Each oil fuel control valve is >100% capacity and only one can be on
AUTO at one time. If operating conditions require the second valve to
be opened it must be under manual control.

BANG

PAKONG 3 / 4 MODULATING CONTROLS

OPERATING PROCEDURE
6

GOVERNOR

POSITION
GOVERNOR.INS 030992

-------------------------------------------------------------------SYSTEM

TURBINE GOVER'NOR

CONT VARIABLE

GOVERNOR VALVE POSITION

CONTROL DEVICE

DEH GOVERNOR LOAD SETTER

SET VALUE

CALCULATED BY UNIT MASTER

GSM PB

"UNIT MSTR"

GRP OPN DISPLAY

001

UNIT MASTER

TX DEVN DISPLAY

089

MASTER

(A)

.'

AIR XMTRS

PERMISSIVES:

(1)

DEH Auto Permissive ON

(2)

DEH IMP Control OFF

(3)

No transmitter deviation:
First Stage Pressure [P1]
Throttle Pressure [Pt]
Megawatt

(4)

MW/P1 comparison agree.

{5)

Unit Master Mode Selected: [CO, BF or BI].

(B)

&

OPERATOR

[MHI]

[MHI]

ACTION

(1)

Select Fuel and Air AUTO [refer relevant Operating Procedure].

(2)

Select Group Operation Display 001 (UNIT MSTR) and ENABLE Subwindow 7,
"Governor Position Demand".

(3)

Check PV and SV [Governor Demand] are tracking and at reasonable value

for existing load. [e.g. at 300MW, PV = 50%)

(5)

Select Governor AUTO.

(6)

Note AUTO indication ON; at this stage MAN indication

[WAITING]. If no AUTO, check permissives and tracking.

is

also

ON.

-2(7)

Select required Unit Master Mode. [Refer Procedure 1)

{Note: If Boiler Follow or Base Input Mode already operating, the
Governor may be selected to AUTO at any time without reselecting the
operating mode.}

(8)

After initialization and balance check, [5 seconds) the selected Unit

Master mode becomes active and the governor (as well as air and fuel)
go to Auto Mode.
The Governor subwindow MANUAL indication goes OFF
when the DEH accepts AUTO condition from the DCIS. If the DEH does not
accept AUTO, the Unit Master governor control rejects to MAN. [Refer to
DEH Operating Instruction.)

(C)

COMMENTS

(1)

In BF and CO Modes, the governor controls the MW output to the value

set at the Target Load subwindow.
In BI Mode, the governor controls
pressure to the value set at the Pressure Set Point subwindow.

(2)

Governor INCREASE is blocked when DEH on Load Limit ON or Pressure is

LOW. Governor DECREASE is blocked when Pressure is HIGH. Refer also
to Required Output block conditions, Instruction 1 [Unit Master] Section
C-4.

(3)

} <L

MANUAL control of governor valves is NOT available from the Unit Master
Governor subwindow.
MANUAL CONTROL OF THE GOVERNOR IS ONLY AVAILABLE FROM THE MHI DEH
GOVERNOR PANEL.

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE

7-FURNACE

ID

PRESSURE

FAN

CONTROLS

DAMPERS
IDFDAMP.INS 030992

-------------------------------------------------------------------SYSTEM

INDUCED DRAFT.

CONT VARIABLE:

FURNACE PRESSURE

PID:

CONT DEVICE:

ID FAN INLET DAMPERS

CDR-127, CDR-128

SET VALUE

(-)

GSM PB

"FURN GAS"

GROUP DISPLAY

003

FURNACE GAS

TX DEVN DISPLAY

089

MASTER & AIR XMTRS

(A)

; j-

20 mm

PERMISSIVES:

(1)

Fan selected for Auto operation ON [running]

(2)

No Furnace Pressure Transmitter Deviation [Monitor ON]

(B)

SGAP401

OPERATOR

ACTION

(1)

Select Group Operation Display 003.

subwindows for ID Fan dampers.

[Press GSM "FURN GAS") and ENABLE

(2)

Check furnace pressure set point.

(3)

Set BIAS adjustment on Fan 1B subwindow at zero [centre-scale].

(4)

Select AUTO for ID Fans in service.

is ON.

(5)

Observe furnace pressure trend for stable operation.

[Normally -20 mm WG].

Note that the Blue AUTO indication

-2-

(c)

COMMENTS:

(1)

Either or both fans may be selected for automatic control.

should be selected immediately after fan start.

AUTO mode

(2)

A separate sub-window [003-1] is provided for the set point.

(3)

ID Fan speed control is normally in AUTO mode. If MANUAL, adjust speed

to produce about 60-70% damper opening at required load.

(4)

If the actual pressure is more than +/- 25mm from the set point, damper
movement which increases the error magnitude is blocked. This applies
in MANUAL and AUTO modes.

(5)

The controlled variable is the median value from three transmitters.

(6)

Display a real time trend of furnace pressure at all times and check
frequently for abnormal patterns. [PID: SGAP401].

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
8

ID

FAN

CONTROLS

SPEED
IDSPEED.INS 030992

SYSTEM

INDUCED DRAFT

CONT VARIABLE

ID FAN SPEED

CCES009,CCES010

CONTROL DEVICE

ID FAN HYDRAULIC COUPLING

3CCE-FAN-1A,

SET VALUE

Calculated from FD average blade pitch

GSM PB

"FURN GAS"

GROUP DISPLAY

003

TX DEVN DISPLAY

N/A

(A)

FURNACE GAS

PERMISSIVES:

(1)

Fan selected for Auto operation is ON [running].

(2)

No Furnace Pressure Transmitter Deviation [Monitor ON].

(3)

Hydraulic coupling selected to REMOTE.

(B)

lB

OPERATOR

ACTION

(1)

Select Group Operation Display 003 ["FURN GAS"] and ENABLE subwindows
for ID Fan hydaulic couplings.

(2)

Adjust BIAS setting on Fan lB subwindow to zero [centre-scale].

(3)

Select AUTO for ID Fans in service.

(4)

Adjust bias setting if required.

-2-

(C)

COMMENTS:

(1)

Either or both fans may be selected for automatic control.

be selected to AUTO immediately after fan start.

Control may

(2)

If furnace pressure is more than +/- 25 mm from the set point, any
speed change command in the direction which increases the error
magnitude is blocked. This applies in MANUAL and AUTO modes.

(3)

The Process Variable is the average speed demand with time constant to
simulate actual speed response. Transfer to AUTO is bumpless, the
speed will slowly go to the calculated set point.

(4)

The minimum speed under auto control is 40%.

speeds as instability [hunting] may occur.

Do not operate at lower

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
g

MOTOR

BOILER

FEED

CONTROLS

PUMPS
MDBFP.INS 030992

-------------------------------------------------------------------SYSTEM

FEEDWATER

CON.T VARIABLE

DRUM LEVEL

CONTROL DEVICE

MDBFP 3A,

SET VALUE

0 mm

GSM PB

"FEED WTR"

GROUP DISPLAY

010

FEEDWATER

TX DEVN DISPLAY

092

CNDS

(A)

3B HYDRAULIC COUPLING SPEED

& FEEDWATER XMTRS

PERMISSIVES:

(1)

Pump selected for auto operation ON

(2)

No transmitter deviation:
feedwater flow [hi range]
first stage pressure
drum level [east, west]

(B)

,c

[MOTOR DRIVEN PUMPS]

OPERATOR

[Running).

ACTION

(1)

Select group operation display 010 [FEED WTR] and ENABLE subwindow of
pumps required on AUTO.

(2)

Check drum level set point.

[Normally 0 mm).
Check level indication
against Hydrostep.
Check feedwater flow PV and SV on Pump 3A
subwindow for track balance and reasonable value for existing load
condition.

(3)

Set BIAS setting on pump 3B to zero [centre-scale].

(4)

Select AUTO for Motor Pumps in service. [Note: The pump speed demand
will go to the minimum value required for pumping at the prevailing
drum pressure.)

(5)

Adjust bias setter if required.

-2-

(C)

COMMENTS:

(1)

The drum level is normally the average of the medians of the east and
west sides The level indication is density compensated over the range
0 - 220 Bar. A separate subwindow is provided for the drum level set
point.

(2}

The feedwater demand FWAF431 is the steam flow (first stage pressure}
plus drum level correction.
When steam flow increases or decreases,
the feedwater flow first goes in the opposite direction to the steam
flow to compensate for drum level swell/shrink effect.
The feedwater
demand is the set value (SV} displayed on pump 3A subwindow. The flow
range is 0-125%ECR.

(3}

The feedwater flow (PV) is indicated on both pump subwindows. The pump
controller adjusts pump speed so that feedwater flow always equals
feedwater demand (SV). The 3B pump subwindow SV is BIAS, range +/- 20%
speed.

(4)

The pump speed range is 2100-7000 r.p.m. for 0-100% control output W
A minimum pump speed bias is calculated from boiler drum pressure.
This factor is added to the speed demand in auto mode.
When a pump is
selected to auto, the speed demand immediately goes to the calculated
minimum value. At this minimum speed the pump pressure is almost equal
to the drum pressure and the pump can immediately contribute flow. The
second pump may be selected to auto at any speed; balancing is
automatic and bumpless.

(5)

When turbine driven pumps are also selected to AUTO, the motor driven
pumps follow the turbine pump controller output. Because of differing
pump characteristics, the percentage flow may not be the same for
turbine and motor pumps.

(6)

If it is necessary to use manual control for drum level, first make a

trend display showing drum level (SGFL407}, feedwater flow (FWAF419} and
steam flow (TGFP400). When level is decreasing, INCREASE the flow; when
level is increasing, DECREASE the flow. DO NOT wait for level to reach
the set point before reversing the flow.
Try to estimate the average
flow for the existing load and work around that point.

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
10

TURBINE

BOILER

FEED

CONTROLS

PUMPS
TDBFP.INS 030992

-------------------------------------------------------------------SYSTEM

FEEDWATER

CONT VARIABLE

DRUM LEVEL

CONTROL DEVICE

TDBFP 2A,

SET VALUE

0 mm

GSM PB

"FEED WTR"

GROUP DISPLAY

010

FEEDWATER

TX DEVN DISPLAY

092

CNDS & FEEDWATER XMTRS

(A)

[TURBINE DRIVEN PUMPS]

DEH GOVERNOR SPEED SETTING

2B

PERMISSIVES:

(1)

Pump selected for auto operation ON

(2)

No transmitter deviation:
Feedwater flow [hi range]
First stage pressure
Drum level [east/west]

(3)

DEH in "Auto" [Remote] mode (TGFZ541 ON)

(B)

OPERATOR

[running].

ACTION

(1)

Select group operation display 010 [FEED WTR] and ENABLE subwindow of
pumps required on AUTO.

(2)

Check drum level set point.

[Normally 0 mm].
Check level indication
against Hydrostep.
Check feedwater flow PV and SV on Pump 2A
subwindow for reasonable value for existing load condition.

(3)

Set BIAS setting on pump 2B to zero [centre-scale].

(4)

Select AUTO for Motor Pumps in service.

The pump speed demand (MV)
will go to the minimum value required for pumping at the prevailing
drum pressure.

(5)

Adjust bias setter if required.

-2-

(C)

COMMENTS:

(1)

The drum level is normally the average of the medians of the east and
west sides The level indication is density compensated over the range
0 - 220 Bar. A separate subwindow is provided for the drum level set
point.

(2)

The feedwater demand FWAF431 is the steam flow (first stage pressure)
plus drum level correction.
When steam flow increases or decreases,
the feedwater flow first goes in the opposite direction to the steam
flow to compensate for drum level swell/shrink effect.
The feedwater
demand is the set value (SV) displayed on pump 2A subwindow. The flow
range is 0-125%ECR.

(3)

The feedwater flow (PV) is indicated on both 2A and 2B subwindows. The

pump controller adjusts pump speed so that feedwater flow always
equals feedwater demand (SV). The 2B pump subwindow SV is BIAS, rang
+/- 20% speed.

(4)

The pump speed range is 2700-5600 r.p.m. for 0-100% control output (MV).
A minimum pump speed bias is calculated from boiler drum pressure.
This factor is added to the speed demand in auto mode.
When a pump is
selected to auto, the speed demand goes to the calculated minimum value.
At this minimum speed the pump pressure is almost equal to the drum
pressure and the pump can immediately contribute flow.
The second
pump may be selected to auto at any speed; balancing is automatic and
bumpless.

(5)

A turbine driven pump cannot be controlled from the DCIS [auto or

manual] unless "DEH AUTO" [Remote] signal is received. When a pump is
NOT "DEH AUTO", the subwindow output [MV] tracks the DEH internal speed
reference [FWAS031, 030].

(6)

Motor driven pumps may be operated on AUTO in parallel with the

turbine pumps.
Because of differing characteristics, the percentage
flow may not be the same for turbine and motor pumps.

(7)

If it is necessary to use manual control for drum level, first make a

trend display showing drum level (SGFL407), feedwater flow (FWAF419) and
steam flow (TGFP400). When level is decreasing, INCREASE the flow; when
level is increasing, DECREASE the flow. DO NOT wait for level to reach
the set point before reversing the flow.
Try to estimate the average
flow for the existing load and work around that point.

12

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
11

DEAERATOR

CONTROLS

LEVEL
DEALVL.INS 030992

-------------------------------------------------------------------SYSTEM

CONDENSATE

CONT VARIABLE

DEAERATOR LEVEL

CONTROL DEVICE

CONDENSATE PUMP SPEED

SET VALUE

LEVEL:

GSM PB

"DEA & CNDS"

GROUP DISPLAY

014

DEA & CONDENSATE

TX DEVN DISPLAY

092

CNDS

(A)

70%

(2132 mm]; PRESSURE: 5 bar

& FEEDWATER XMTRS

PERMISSIVES:

(1)

Selected Condensate Pump "ON"

(2)

No Condensate Flow transmitter deviation

(3)

No Deaerator Level transmitter deviation

(B)

3FWC-P-1A, lB, lC

OPERATOR

ACTION

(1)

Select group operation

required on AUTO.

(2)

Check set point for deaerator level and condensate pressure.

(3)

Set bias settings to zero [centre-scale].

(4)

Select AUTO for pumps in service.

(5)

Adjust bias setters if required.

( C)

display

014

and

ENABLE

subwindow

of

pumps

COMMENTS:

(1}

The minimum speed demand for auto operation is 30% speed.

(2)

Under normal conditions, the condensate pressure will be greater than

the minimum set point.
If the pressure falls below the minimum
pressure, the level control is suspended and the pump speed is
adjusted to maintain the required pressure.

(3)

If deaerator level is greater than 90% [2525 mm], the deaerator high
level controller opens overflow valves ACV-170, 173 and dumps the
excess condensate to the condenser. The high level control is always
in auto mode. [GSM: "DEA MISC"]

BANG

CONTROLS

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
12

CONDENSER

LEVEL
CONDLVL.INS 030992

-------------------------------------------------------------------SYSTEM

CONDENSATE

CON.T VARIABLE

CONDENSER LEVEL

CONTROL DEVICE

NORMAL MAKE UP-VALVE

EMERGENCY MAKE-UP VALVE
CONDENSATE DUMP VALVE

SET VALUE MAKEUP

70%

SET VALUE DUMP

90%

GSM PB

"DEA

GRP OPN DISPLAY

014

DEA

TX DEVN DISPLAY

098

HEATER LEVEL XMTRS

(A)

(1)

(B)

CNDS"

&

CONDENSATE

PERMISSIVES
No condenser level transmitter deviation.

OPERATOR

[Monitor ON].

ACTION

(1)

Check level transmitters for reasonable value [Tx Display 098].

OK, select transmitter 1 and monitor ON.

If both

(2)

Select Group Operation Display

Subwindows 6,7,8. [ACV-54, 57, 63]

ENABL ....

(3)

Adjust set points [SV] to required value.

(4)

Select AUTO for the three valves [ACV-54, 57, 63]

(C)

) I..J.

&

ACV-54
ACV-57
ACV-63

014

[DEA

&

CONDENSATE]

and

COMMENTS

(1)

Under normal operating conditions, condensate losses will be made up by

valve ACV-54.
Valves ACV-57 and ACV-63 will be shut.
Emergency
Makeup Valve ACV-57 will open if high water loss causes ACV-54 to be
100% open.

(2)

Changes in operating conditions can cause a transient increase of

condenser level.
The make-up valves ACV-57 and ACV-54 close as the
level approaches the set value.
Above the set value, both make-uo
valves are closed. If the level is greater the dump set value, the dur
valve ACV-63 opens. The opening is proportional to the leve~ deviation.

BANG

PAKONG 3 / 4 MODULATING CONTROLS

OPERATING PROCEDURE

13

SECONDARY SUPERHEATER
TEMPERATURE

OUTLET
SECSHO.INS 030992

-------------------------------------------------------------------SYSTEM

MAIN STEAM

CONT VARIABLE

SECONDARY SUPERHTR OUTLET TEMPERATURES 2A,2B

CONTROL DEVICE

1ST STAGE DESH

lC: ACV-357 &
lD: ACV-368 &
1A: ACV-227 &
lB: ACV-319 &

SET VALUE

CALCULATED FROM BOILER LOAD.

GSM PB

"SSHA SPRAY" [TO STEAM LINE 2A FROM DESH 1C, 1D]

"SSHB SPRAY" [TO STEAM LINE 2B FROM DESH 1A, 1B]

GROUP DISPLAY

006
007

SEC SH TO 2A LINE
SEC SH TO 2B LINE

TX DEVN DISPLAY

094

STEAM TEMP XMTRS #1

(A)

lA,lB,lC,lD SPRAY CONTROL VALVES

ACV-362
ACV-373
ACV-232
ACV-325

PERMISSIVES

(1)

No thermocouple deviation [Monitors ON].

(2)

No first stage pressure deviation [Monitor ON].

(3)

Modulate permit from BVI logic ON.

(4)

No CLOSE VALVE command from BVI logic.

(B)

[Refer B(3)]

OPERATOR

ACTION

(1)

Check thermocouples
agreement.

[Display

094]

for

reasonable

(2)

Select group operation display 006 [GSM: SSHA SPRAY].

subwindows for set value and for valves required for operation.

(3)

Select AUTO on set point subwindow [1]. If manual set point required,
select MAN and adjust set value to the required temperature.

(4)

Select AUTO for DESH 1C,1D required spraywater valves.

(5)

Select group operation display 007 [GSM:

subwindows for valves required for operation.

(6)

Select AUTO for DESH 1A,1B required spraywater valves.

SSHB

values

SPRAY].

and

pair

ENABLE

ENABLE

-2-

(C)

}_ I

COMMENTS

(1)

There are three sections of main steam superheating;

PRIMARY
(uncontrolled), SECONDARY (controlled by the first stage desuperheaters
lC,lD,1A,lB) and TERTIARY [FINAL] (controlled by the second stage
desuperheaters 2A and 2B).

(2) .

The steam lines from each side of the secondary superheater outlet
header CROSS OVER before going to the second stage desuperheaters 2A
and 2B. [DESH 1C,1D -> 2A; 1A,1B -> 2B]

(3)

A separate control system is provided for each side of the secondary

superheater. The same set value is used for each system.

(4)

Each desuperheater has two 100% spray valves.

AUTO at the same time.

(5)

The set point subwindow appears on group operation displays 006 ana
007. Either may be used.

(6)

A separate instruction is provided for the tertiary superheater outlet

temperature control.

Only ONE valve can be

BANG

PAKONG 3 / 4 MODULATING CONTROLS

OPERATING PROCEDURE

TERTIARY

14

(FINAL)
SUPERHEATER
TEMPERATURE

OUTLET

TERSHO.INS 030992

-------------------------------------------------------------------SYSTEM

MAIN STEAM

CONT VARIABLE

TERTIARY SUPERHTR OUTLET TEMPS

CONTROL DEVICE

2ND STAGE DESH 2A,2B SPRAY CONTROL VALVES

2A:
ACV-215 & ACV-220
2B :
ACV-330 & ACV-336

SET VALUE

CALCULATED FROM BOILER LOAD

GSM PB

"TSH SPRAY"

GROUP DISPLAY

008

TX DEVN DISPLAY

094,095

(A)

') 7

[Refer B(3)]

TERTIARY SH
STEAM TEMP XMTRS #1,#2

PERMISSIVES

(1)

No thermocouple deviation [Monitors ON].

(2}

No first stage pressure deviation [Monitor ON].

(3}

Modulate permit from BVI logic ON.

(4}

No CLOSE VALVE command from BVI logic.

(B)

(WEST,EAST)

OPERATOR

ACTION

(1)

Check thermocouples
agreement.

[Display

094,095]

for

reasonable

values

and pair

(2)

Select group
operation display
008
[GSM:
"TSH SPRAY"].
subwindows for set value and for valves required for operation.

(3)

Select AUTO on set point subwindow [1].

I f manual set point required,
select MAN and adjust set value to the required temperature [Usually
540 deg].

(4)

Select AUTO for DESH 2A,2B required spraywater valves.

ENABLE

-2-

(C)

COMMENTS

(1)

There are three sections of main steam superheating; PRIMARY

(uncontrolled), SECONDARY (controlled by the first stage desuperheaters
lC,lD,lA,lB) and TERTIARY [FINAL] (controlled by the second stage
desuperheaters 2A and 28).

(2)

The steam lines from each side of the secondary superheater outlet
header CROSS OVER before going to the second stage desuperheaters 2A
and 2B.
[DESH lC,lD -> 2A; lA,lB -> 2B]
The second stage
desuperheaters
2A,
2B
control
the
tertiary superheater outlet
temperatures [West, East].

(3)

A separate control system is provided for each side of the tertiary

[final] superheater. The same set value is used for each system.

(4)

Each desuperheater has two 100% spray valves.

AUTO at the same time.

(5)

A separate instruction is provided for the secondary superheater outlet

temperature control.

0nly ONE valve can

BANG

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
15

CONTROLS

REHEAT STEAM TEMPERATURE

[GAS RECIRCULATION]
GASRECRCT.INS 030992

--------------------------------- ~ ----------------------------------

SYSTEM

REHEAT STEAM

CONT VARIABLE

REHEAT STEAM TEMPERATURE

CONTROL DEVICE

GAS RECIRCULATION FANS 2A,

SET VALUE

540 DEG

GSM PB

"RE HTR"

GROUP DISPLAY

009

REHEATER TEMP

TX DEVN DISPLAY

095

STEAM TEMP XMTRS #2

(A)

2.

CDR-125,

CDR-126

PERMISSIVES

{1)

No thermocouple deviation; West/East.

(2)

No First Stage Pressure transmitter deviation.

{3)

No Boiler Trip.

(4)

Selected fan ON [Running].

(B)

2B

OPERATOR

ACTION

{1)

Check thermocouples
agreement.

[Display

095}

for

reasonable

value

and

pair

{2)

Select Group Operation Display 009 ["RE HTR"] and ENABLE subwindows for
Burner Tilt and Gas Recirculation Fans.

{3)

Adjust BIAS setting on Fan 2B subwindow to zero [centre scale].

{4)

Adjust reheat steam temperature set point on Fan 2A to required value

[540 Deg at normal load].

(5)

Select AUTO on Burner Tilt subwindow.

(6)

Select AUTO on Gas Recirculation Fans subwindows.

(7)

Adjust GR Fan bias setter if required.

-2-

(C)

COMMENTS

(1)

The maximum reheat steam set point reduces as boiler load decreases.
This maximum value overrides the operator set point.
Refer function
generator FG-78.

(2)

The GR Fan inlet vanes have a minimum position when in AUTO mode.
minimum varies with load.

(3) .

The maximum inlet vane position is limited by motor current; the

maximum value is 100 Amps.
The maximum current control overrides
temperature control.

(4)

Burner tilt position is controlled as a

percentage oil fuel.

The

function of boiler load and

BANG
16

PAKONG 3 / 4 DCIS MODULATING

OPERATING PROCEDURE
REHEAT

STEAM

TEMPERATURE

CONTROLS
[SPRAYS]

RHSPRAYS.INS 030992

-------------------------------------------------------------------REHEAT STEAM

CONT VARIABLE

REHEAT STEAM TEMPERATURE

CONTROL DEVICE

REHEAT DESH 3A, 3B

SET VALUE

540 DEG [+5 DEG when GR Fan AUTO]

GSM PB

"RE HTR"

GROUP DISPLAY

009

REHEATER TEMP

TX DEVN DISPLAY

095

STEAM TEMP XMTRS #2

(A)

[ACV-241,246,257,262]

PERMISSIVES

(1)

No thermocouple deviation [Monitor ON]

(2)

Modulate permit from BVI Logic ON

(3)

No CLOSE command from BVI Logic

(B)

}I

\.

SYSTEM

OPERATOR

ACTION

(1)

Check thermocouples for reasonable value and pair agreement

(2)

Select Group Operation Display 009. [Press GSM "RE HTR"] and ENABLE
subwindows for required control valves.

(3)

Check set point [Gas Recirculation Fan 2A subwindow]

(4)

Set BIAS adjustment on RH spray bias subwindow at zero.

(5)

Select AUTO for required RH spray valves

(6)

Adjust bias setter if required.

-2-

(C)

COMMENTS

(1)

Under normal conditions, the Reheat temperature is controlled by the

Gas Recirculation Fans.
The set point for the reheat spray valves
controller is 5 deg higher than the GR fans and the valves are normally
closed. . If the temperature is more than 5 deg above the set point, the
spray valves open to provide " back-up control.
If the GR fans are
manual, the 5 deg bias is removed and the sprays control to the set
point.

(2)

Both desuperheaters 3A and 3B must be selected to AUTO.

valve of each pair can be AUTO.

Only ONE