Controls of Super Critical 3

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Feb 2009
(O)I)O OI +T1) ()1I1(/ O11)
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Controls of Super Critical 3
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Feb 2009
Boiler Turbine Control
Controls of Super Critical 3
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Feb 2009
Boiler ollowing Mode
Controls of Super Critical 3
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Feb 2009
%:rbine ollowing Mode
Controls of Super Critical 3
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Feb 2009
Coordinate Mode Control
Controls of Super Critical 3
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Feb 2009
Coordinate Mode Control
Controls of Super Critical 3
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Feb 2009
rum and OT Control Comparison
Controls of Super Critical 3
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Feb 2009
rum and OT Control Comparison
Controls of Super Critical 3
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Feb 2009
OT Control Overview
Controls of Super Critical 3
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Feb 2009
Cycle of S:5ercritical Power Plant
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
S:5ercritical Power Plant
Controls of Super Critical 3
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Feb 2009
OT Control Overview
Controls of Super Critical 3
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Feb 2009
OT Start up Control mode
Controls of Super Critical 3
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Feb 2009
Super Critical Units Controls Mode
Controls of Super Critical 3
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Feb 2009
lushing Mode
Controls of Super Critical 3
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Feb 2009
lushing Mode
Controls of Super Critical 3
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Feb 2009
Start-Up System with Recirculation
HPH
BFP
Deaerator

WW
ECO
To Condenser

HWL
SH
Start-Up System
Recirculation Pump in Main Bypass Line
S
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p
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F
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T
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Controls of Super Critical 3
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Feb 2009
Start UP System
Controls of Super Critical 3
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Feb 2009
START-UP
1 the water system o1 the boiler is empty (economizer, 1urnace walls,
separators), then the system is 1illed with approximately 10 TMCR
1eed water 1low.
When the level in the separator reaches set-point, the WR valve will
begin to open.
When the WR valve reaches ~30 open 1or approximately one minute,
then increase 1eed water 1low set-point to 30 TMCR. As the 1low
increases, WR valve will reach 1ull open and ZR valve will begin to
open.
The water system is considered 1ull when:
The separator water level remains stable 1or two(2) minutes
and
The WR valve is 1ully opened and ZR valve is ~15 open 1or two(2)
minutes.
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
SEPARA1OR S1ORACE 1AAK LEJEL
COA1ROL
W Se5arator level is maintained by the combined action of a se5arator storage
tank level feed water demand and the 5ositioning of WR and ZR drain
valves.
W eed water demand is develo5ed in res5onse to se5arator storage tank level
error and total f:el flow so as to 5revent tank level from dro55ing too low.
W %he WR and ZR valves are controlled in a s5lit range manner to maintain
the liq:id level once the level reaches a high limit.
W %he WR valve will res5ond first and then the ZR when the WR exceeds its
linear o5erating range.
W %ank geometry is s:ch that fl:ct:ations in tank level are very dynamic, for
this reason, only 5ro5ortional control action established thro:gh the WR/ZR
f:nction c:rves is :sed to 5osition these valves in res5onse to level error.
Controls of Super Critical 3
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Feb 2009
&C JALJE COA1ROL
Control objective:
Maintain minimum economizer inlet 1low.
Control action:
W The boiler circulating pump is started 1ollowing the start o1 a
turbine-driven 1eed water pump and the 1inal clean-up cycle. This
pump circulates 1eed water 1rom the evaporator outlet back to the
economizer inlet.
W ocated at the outlet o1 this pump is the UG valve which
controls economizer inlet 1low during the start-up phase o1 operation.
emand 1or this recirculation control valve is established based on
measured economizer inlet 1low compared to a minimum boiler
1low set point.
Controls of Super Critical 3
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Feb 2009
Separator water circuit o1 Super Critical
Controls of Super Critical 3
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Feb 2009
EEDWA1ER COA1ROL LOOP
Control objective:
W evelop total unit 1eed water demand as required to support unit
load.
W Adjust 1eed water demand to maintain desired separator outlet
temperature.
W Adjust separator outlet temperature set point as required to maintain
acceptable platen superheat spray control range.
W ncorporate separator storage tank level (wet mode) 1eed water
demand.
W Maintain minimum required economizer inlet 1low.
.
Controls of Super Critical 3
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Feb 2009
eedwater Control
aturaI circuIation boiIer Once-through boiIer
eedwater
control
Level
eedwater
Steam flow
m

Eva Eco
T
T
Enthalpy
eedwater
control
eedwater
T P
Eco
Eva
Controls of Super Critical 3
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Feb 2009
eed water 1iring rate ratio control
Controls of Super Critical 3
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Feb 2009
eed water 1iring rate ratio control
Controls of Super Critical 3
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Feb 2009
Process Set5oint
eed
orward
1(x)

K
d
dt
P
+/-
C
-/+
C
+/-
P
+/-

%
MO

eed orward with model

Controls of Super Critical 3
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Feb 2009
5rocess set5oint

K
d
dt

P
+/-
C
-/+

C
+/-
P
+/-
1(x)
PROCESS

K
d
dt

P
+/-
C
-/+
1(x)
%
C
+/-
P
+/-
eed orward
Controls of Super Critical 3
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Feb 2009
tsec]
0 60 120
C
180 240 300
Water wall %em5erat:re
MW
_

:el with model

%:rbine set5oint
Witho:t model
Model predictive control
)46)
Controls of Super Critical 3
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Feb 2009
iring Rate Master
Controls of Super Critical 3
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Feb 2009
uel Rate Master
Controls of Super Critical 3
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Feb 2009
eed orward iring Rate Control
Controls of Super Critical 3
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Feb 2009
eed orward iring Rate Control
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
uhuan 4x1000MW Preparation o1 light o11
Controls of Super Critical 3
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Feb 2009
M:lti-comb:sting Nozzles with Se5arated
Overfire Air Dam5er
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
Controls of Super Critical 3
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Feb 2009
START-UP contd..
ater flows through the economizer and evaporator, and discharges the boiler through
the R valve to the flash tank and via connecting pipe to the condenser.
Start BP and open the UG valve to establish minimum water wall flow
at 30% TMR.
As the pressure is raised, 1irst the WR and then the ZR valves will open when
Wseparator water level increases due to boiler water swell. As pressure 1urther
Wincreases, the WR and ZR valves will start to close as the water level decreases.
WThe steam temperature at the separator inlet will reach a stable superheated
Wcondition at app. 30 TMCR, causing the level in the separator to decrease and
Weventually disappear. The boiler is now in once-through mode (dry mode). The
WBCP (Boiler Circulating Pump) will be stopped automatically.
t is extremely important that minimum water wall flow be maintained at all times when
firing the boiler to prevent tube damage due to overheating.
Controls of Super Critical 3
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Feb 2009
EEDWA1ER COA1ROL LOOP contd..
emand 1or 1eed water is established predominately by the Boiler Master demand.
This signal, processed though a boiler trans1er 1unction provides the 1eed
1orward component o1 the total 1eed water demand.
The boiler trans1er 1unction is a tunable dynamic element providing a means to
dynamically match the 1eed water 1eed 1orward demand to actual evaporator heat
trans1er.
Optimization o1 the 1eed 1orward in this manner minimizes temperature
1luctuations that may otherwise result 1rom varying dynamic response between the
1iring and 1eed water control systems (as they relate to evaporator heat trans1er)
thereby lessening the dependence on 1eedback correction.
Controls of Super Critical 3
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Feb 2009
EEDWA1ER COA1ROL LOOP contd..
The 1irst controller acts on a load dependent average platen spray di11erential
temperature.
ts output represents the required adjustment to evaporator heat trans1er/steam
generation to maintain both the steam conditions and 1lue gas temperatures
entering the platen superheat section so as to ensure adequate platen spray control
range.
A second controller acts on a load dependent separator outlet temperature set
point corrected by the platen spray di11erential temperature controllers output.
This controller acts to adjust 1eed water in response to 1iring system disturbances
and the relatively 1ast e11ect they have on separator outlet steam temperatures.
The overall combined 1eed water 1eedback control action is such that 1eed water
demand is responsive to changes in the overall unit heat trans1er pro1ile.
Controls of Super Critical 3
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Feb 2009
EEDWA1ER COA1ROL LOOP contd..
The combined 1eed 1orward/1eedback demand signal is subject to a minimum
economizer inlet 1low set point (wet mode) activated i1 the boiler circulation pump
is not in service and the unit is being 1ired.
This ensures the minimum economizer inlet cooling 1low is maintained by the
1eed water supply system in the event the start-up system is not available.
The 1eed 1orward/1eedback demand signal is subject to a second wet mode 1eed
water demand developed to support separator storage tank level control.
The resulting demand provides the set point to a 1eed water master controller.
The fuel/feed water ratio protection logic provides overriding control of individual
feeder speed demands in the event of an excessively high fuel to feed water ratio.
Controls of Super Critical 3
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Feb 2009
TH^\K Y' TH^\K Y'