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KOLAGHAT THERMAL POWER STATION

AIR FLOW CONTROL


FUEL MASTER
COMBUSTION CONTROL

Presented by:

K. N. Samanta, Manager(P.S.), PCI-OPH, KTPS,


30 th May2016
WBPDCL

PID Controller (ProportionalIntegralDerivative)

Plot of PV vs time, for three values of K p(Kiand


Kdheld constant)

Plot of PV vs time, for three values of K i(Kpand


Kdheld constant)

Plot of PV vs time, for three values of K d(Kpand


Kiheld constant)

Effects of varying PID parameters (Kp,Ki,Kd) on the step


response of a system.

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AIR FLOW CONTROL

Load Vs. Coal / Air Flow / Steam Flow (Coal Rate


0.80)

COAL RATE :: 0.80 Kg/kwh


LOAD (MW)

COAL
FLOW(TPH)

AIR
FLOW(TPH)

STEAM
FLOW(TPH)

0
70
110
120
130
140
150
160
170
180
190
200
210

0
56
88
96
104
112
120
128
136
144
152
160
168

0
285
449
490
530
570
615
655
695
735
775
815
858

0
225
350
385
415
450
480
512
545
576
608
640
670

Load Vs. Coal / Air Flow / Steam Flow (Coal Rate


0.80)

O2 Deviation (%) Vs. O2 Trimming


O2 Deviation
(%)

O2 Trimming

0.80

10

0.84

20

0.88

30

0.92

40

0.96

50

1.00

60

1.04

70

1.08

80

1.12

90

1.16

100

1.20

CV Corrected Total Fuel Flow

FD FAN :: BIAS

FD FAN 5A VANE COMMAND : PID.OP + (BIAS


50)

Lag Time Vs. Rate

Lag 1

Time
Lag 2
(Sec)

Rate
(%)

0.1

30

10%

0.1

0.1

40

5%

0.1

0.2

60

3%

0.2

0.4

90

2%

0.4

0.6

150

1%

AIR FLOW CONTROL :: TREND

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MILL - AIR FLOW CONTROL

MILL - AIR FLOW CONTROL


Mill Air Flow SP of Mill Air Flow CLCS is Variable SP.
This SP will follow the following Curve of RPM Vs. Mill
MILL AIR FLOW
Air Flow.
MILL-AIR

(40 - 60 TPH)

RPM
0
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
10

MILL-AIR
40
40
40
42
44
46
48
50
52
54
56
58
60
60

65

60

60

60

58
56

55

54
52

50

50
48
46

45

44
42

40

40

40 40

35
0

10

12

MILL - AIR FLOW CONTROL


We can change this SP with the help of BIAS. Following Curves
are showing with +/- 3 biasing (AIR MAX LIMIT: 60 TPH & AIR
MIN LIMIT: 40 TPH)
MILL-AIR (+3 BIAS)

MILL-AIR (-3 BIAS)


60

65
60
60

59
57
55
53
51
49
47
45
43

55
50
45
40

43

60

60

55

50

45

40

43

40

40
40

57
55
53
51
49
47
45
43
41
40

57

35

35
0

10

12

10

12

N.B.:- We have to set minimum deviation between Process Value


(PV) & Set Pint (SP) with the help of biasing (if required) before
putting the Hot Air Damper of Mill Air Flow in Auto Mode

FUEL MASTER

FUEL MASTER in AUTO

We have to set minimum deviation between


Process Value (PV) & Set Pint (SP) before
putting the Fuel Master in CAS Mode.
Then we should follow this equation before
putting the Feeders in AUTO Mode.
(PID.OP) = (CMMD.
FEEDER) (BIAS)

Mill AMPS Supervision


MILL AMPS - MAX LIMIT (41):
If Mill Amps exceeds MILL AMPS MAX LIMIT, then
Feeder command will freeze to last value. Then to
reduce the Mill Amps, We have to give +ve BIAS to
respective Feeder. The feeder command will unfreeze
when Mill Amps will reduce more than 2 AMPS i.e. 39
Amps (Band: 2).
MILL AMPS - MIN LIMIT:
If Mill Amps lower than MILL AMPS MIN LIMIT, then
Feeder Final Command will be zero & Mill Air
Flow SP will reduce to 40 TPH. But Feeder will
remain still in Auto Mode.
Note: This Supervision will be available only in AUTO

Feeder Supervision

Feeder RMP Supervision:


If we set Feeder RMP MAX LIMIT to
7, in any condition speed will not
increase beyond 7 rpm.
ALL FEEDER MAN:
If we press ALL FEEDER MAN
button, then all feeder will be in
MAN Mode.

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Combustion Control

Load Vs. Coal / Air Flow / Steam Flow (Coal Rate


0.80)

COAL RATE :: 0.80 Kg/kwh


LOAD (MW)

COAL
FLOW(TPH)

AIR
FLOW(TPH)

STEAM
FLOW(TPH)

0
70
110
120
130
140
150
160
170
180
190
200
210

0
56
88
96
104
112
120
128
136
144
152
160
168

0
285
449
490
530
570
615
655
695
735
775
815
858

0
225
350
385
415
450
480
512
545
576
608
640
670

Load Vs. MS Pressure

LOAD Vs. MS-Pr.


140.00

120.00

100.00

80.00

60.00

40.00

20.00

0.00
0.00

50.00

100.00

150.00

200.00

250.00

MS Pressure Vs. LOAD / COAL (COAL RATE : 0.50


0.90)
MS LOA
PR
D
1

1.72

3.44

5.16

6.88

8.60

6
7
8
9
10

10.3
2
12.0
4
13.7
6
15.4
8
17.2

MS
FLO
W
5.50
11.0
1
16.5
1
22.0
2
27.5
2
33.0
2
38.5
3
44.0
3
49.5
4
55.0

COAL (TPH)
@
Coal Rate :
0.50

COAL (TPH)
@
Coal Rate :
0.60

COAL (TPH)
@
Coal Rate :
0.70

COAL (TPH)
@
Coal Rate :
0.80

COAL (TPH)
@
Coal Rate : 0.90

0.86

1.03

1.20

1.38

1.55

1.72

2.06

2.41

2.75

3.10

2.58

3.10

3.61

4.13

4.64

3.44

4.13

4.82

5.50

6.19

4.30

5.16

6.02

6.88

7.74

5.16

6.19

7.22

8.26

9.29

6.02

7.22

8.43

9.63

10.84

6.88

8.26

9.63

11.01

12.38

7.74

9.29

10.84

12.38

13.93

8.60

10.32

12.04

13.76

15.48

FACTOR :: LOAD / MS Pressure / STEAM FLOW /


COAL

Load (Steam Flow) / 3.2


Load (MS Pr.) * 1.72
Steam Flow (MS Pr.) * 5.504
Coal Flow (@ Coal Rate: 0.80)
(Steam Flow) / 4

Combustion Control

Combustion Control
Boiler tuning is something of a balancing act. The Boiler controls the Turbine
throttle pressure by modulating the boiler firing rate. This means that the
amount of fuel and air that is going into the furnace is increased or decreased
depending on whether the Turbine requires more or less steam pressure.

The main object of the Combustion Control System is to keep steam pressure
stable and response the load changes rapidly, achieve optimum combustion
efficiency and keep furnace negative pressure stable.

There are basically three nos. of corrections (Steam Flow Correction, Drum Pr.
Correction & Turbine I/L Pr. Correction) are added & converted into Coal
(BM_COAL) as per Curve (Steam Flow Vs. Coal Flow) in Combustion Control
System. Finally the objective of Combustion Control System is to generate a
demand signal for Fuel (BM_COAL) and Air Flow Controls (BM_AIR).

BM_COAL = Coal
Coal (Drum Pr. Correction)

(Turbine I/L Pr. Correction)

+ Coal

(Steam Flow Correction)

BM_COAL is used as Remote Set Point (RSP) of FUEL MASTER CONTROL.


Finally CV corrected BM_COAL [BM_COAL(CV CORRECTION)] again converted into
BM_AIR as per Curve (Coal Flow Vs. Air Flow) in Combustion Control System

Turbine I/L Pressure Correction


The steam Pressure at Turbine I/L is measured by three transmitters. The
selected transmitter output is compared with Turbine I/L Pressure Set
Point. The error is applied to a PID Controller. Main functions of this
Turbine I/L Pressure correction are supply extra coal during Coal
Rate changes & minimize the deviation of Turbine I/L Pressure Set Point
with Turbine I/L Pressure. This correction system is a typical time
delays system & synchronized with Boiler response time.

The key to tuning the Boiler Master is balancing the Proportional, Integral
& Derivative action of the controller so that the pressure is maintained
with good control, moves toward the set point in a timely manner &
correctly anticipates the movement of the error signal. In general, the
Proportional gain will be fairly large, the Integral action slow & the
Derivative gain in the controller should be relatively small.

Coal (Turbine I/L Pr. Correction) = (MS Factor) * (PID_OP) / 4


Where
PID_OP Max : +1500
PID_OP Min : -1500
MS Factor
: 0.2

Stem Flow Correction


The main steam pressure change is mainly caused by the coal flow
changes and main steam flow changes. In normal operation conditions,
the variations of main steam flow are very small. Especially in steady
conditions, the main steam flow can be considered as stable.
Due to this reason Steam Flow was considered as primary
parameter of this Combustion Control System.
Now corrected Steam flow is the measured Steam flow multiplied by the
ratio of Turbine I/L Pressure Set Point to Turbine I/L Pressure. The dynamic
nature of this ratio helps the Boiler master move in the right direction.
The signal from rate of change of Steam Flow is used as a fast controlling
signal, which also is superimposed on the PID controller output.

Coal (Steam Flow Correction) =


[Steam Flow * (Turb I/L Pr. SP / Turb I/L Pr.)] * (Steam Flow Factor)
/4
Where

Steam Flow Max : 670

Steam Flow Factor

: 0.5

Drum Pressure Correction

The signal from rate of change of Drum


Pressure is used as an anticipatory signal
by superimposing this to the PID
controller output.

Coal (Drum Pr. Correction) =


Limit [-16, {(Drum Pr. Factor) * [(Turb I/L Pr. SP) (Drum
Pr. / 1.16885)}, 16] / 4
Where

Drum Pr. Factor

: 5.504

Combustion Control System in AUTO Mode


1. Put AIR FLOW CONTROL & FUEL MASTER into CAS Mode.
2.

Set Allowable MAX Coal Limit to Maximum value.

3.

OP (%) of MS-PID should be 0 in MAN mode.

4.

(ACTUAL COAL) = (BM_COAL) +/- (BIAS)


We have to set minimum deviation between BM_COAL &

ACTUAL COAL
with the help of BIAS.
5.

Select REM SP of FUEL MASTER.

6. Finally put MS-PID in AUTO Mode.

NOTE: If MS-PID.OP reaches either Max level (+1500) or Min level


(-1500) or Allowable MAX Coal Limit reaches to Maximum value,
then we should Put this loop in AUTO Mode again from STEP-2. (If
we adjust BIAS in AUTO Mode. i.e. if we change BIAS by +/-5, then

Combustion Control

Since the Combustion system of coal-fired


Boiler in thermal power plant is characterized
as time varying and non-linear, it is hard to
achieve a satisfactory performance by the
conventional
Proportional-Integral-Derivative
(PID) control scheme. Further Total Coal Flow in
Unit#5 is measured from Feeder Speed (6
TPH/RPM) & we dont know the actual weight of
Coal Flow. This is the major difficulties of this
Control Loop.
Total Coal Flow(TPH) = Feeder Speed
(A, B, C, D, E, F) * 6

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THANK YOU
Kolaghat Thermal Power Station,

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