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CONTROLS OF SUPER CRITICAL BOILERS Presentation By AJAY SHUKLA Sr.Faculty PMI, Controls of Super Critical 3 rd Feb 2009 Boiler Turbine Control Controls of Super Critical 3 rd Feb 2009 Boiler Following Mode Controls of Super Critical 3 rd Feb 2009 Turbine Following Mode Controls of Super Critical 3 rd Feb 2009 Coordinate Mode Control Controls of Super Critical 3 rd Feb 2009 Coordinate Mode Control Controls of Super Critical 3 rd Feb 2009 Drum and OT Control Comparison Controls of Super Critical 3 rd Feb 2009 Drum and OT Control Comparison Controls of Super Critical 3 rd Feb 2009 OT Control Overview Controls of Super Critical 3 rd Feb 2009 Cycle of Supercritical Power Plant Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 Supercritical Power Plant Controls of Super Critical 3 rd Feb 2009 OT Control Overview Controls of Super Critical 3 rd Feb 2009 OT Start up Control mode Controls of Super Critical 3 rd Feb 2009 Super Critical Units Controls Mode Controls of Super Critical 3 rd Feb 2009 Flushing Mode Controls of Super Critical 3 rd Feb 2009 Flushing Mode Controls of Super Critical 3 rd Feb 2009 Start-Up System with Recirculation Separator SH WW ECO C Flash Tank Start-Up System Recirculation Pump in Main Bypass Line HWL C To Condenser Deaerator C HPH BFP Controls of Super Critical 3 rd Feb 2009 Start UP System Controls of Super Critical 3 rd Feb 2009 START-UP If the water system of the boiler is empty (economizer, furnace walls, separators), then the system is filled with approximately 10% TMCR feed water flow. When the level in the separator reaches set-point, the WR valve will begin to open. When the WR valve reaches >30% open for approximately one minute, then increase feed water flow set-point to 30% TMCR. As the flow increases, WR valve will reach full open and ZR valve will begin to open. The water system is considered full when: The separator water level remains stable for two(2) minutes and The WR valve is fully opened and ZR valve is >15% open for two(2) minutes. Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 SEPARATOR STORAGE TANK LEVEL CONTROL • Separator level is maintained by the combined action of a separator storage tank level feed water demand and the positioning of WR and ZR drain valves. • Feed water demand is developed in response to separator storage tank level error and total fuel flow so as to prevent tank level from dropping too low. • The WR and ZR valves are controlled in a split range manner to maintain the liquid level once the level reaches a high limit. • The WR valve will respond first and then the ZR when the WR exceeds its linear operating range. • Tank geometry is such that fluctuations in tank level are very dynamic, for this reason, only proportional control action established through the WR/ZR function curves is used to position these valves in response to level error. Controls of Super Critical 3 rd Feb 2009 UG VALVE CONTROL Control objective: Maintain minimum economizer inlet flow. Control action: • The boiler circulating pump is started following the start of a turbine-driven feed water pump and the final clean-up cycle. This pump circulates feed water from the evaporator outlet back to the economizer inlet. • Located at the outlet of this pump is the UG valve which controls economizer inlet flow during the start-up phase of operation. Demand for this recirculation control valve is established based on measured economizer inlet flow compared to a minimum boiler flow set point. Controls of Super Critical 3 rd Feb 2009 Separator water circuit of Super Critical Controls of Super Critical 3 rd Feb 2009 FEEDWATER CONTROL LOOP • • • • • . Control objective: Develop total unit feed water demand as required to support unit load. Adjust feed water demand to maintain desired separator outlet temperature. Adjust separator outlet temperature set point as required to maintain acceptable platen superheat spray control range. Incorporate separator storage tank level (wet mode) feed water demand. Maintain minimum required economizer inlet flow. Controls of Super Critical 3 rd Feb 2009 Feedwater Control Natural circulation boiler • m Once-through boiler Steam flow T Enthalpy T P T Level Feedwater control Eco Eva Eva Feedwater control Eco Feedwater Controls of Super Critical Feedwater 3 rd Feb 2009 Feed water firing rate ratio control Controls of Super Critical 3 rd Feb 2009 Feed water firing rate ratio control Controls of Super Critical 3 rd Feb 2009 Feed Forward with model Process Setpoint f(x) Feed Forward MODEL S P +/- C -/+ D d K dt C +/- P +/- X Controls of Super Critical 3 rd Feb 2009 Feed Forward FF PROCESS process setpoint f(x) P +/- C -/+ D d K dt C +/- Controls of Super Critical f(x) P +/- C -/+ D d K dt P +/- S FF C +/- P +/- X 3 rd Feb 2009 Model predictive control + MW _ Fuel with model Without model Turbine setpoint Water wall Temperature C 0 60 Controls of Super Critical 120 180 240 300 t[sec] 3 rd Feb 2009 Firing Rate Master Controls of Super Critical 3 rd Feb 2009 Fuel Rate Master Controls of Super Critical 3 rd Feb 2009 Feed Forward Firing Rate Control Controls of Super Critical 3 rd Feb 2009 Feed Forward Firing Rate Control Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 Yuhuan 4x1000MW Preparation of light off Controls of Super Critical 3 rd Feb 2009 Multi-combusting Nozzles with Separated Overfire Air Damper Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 Controls of Super Critical 3 rd Feb 2009 START-UP contd.. Water flows through the economizer and evaporator, and discharges the boiler through the WR valve to the flash tank and via connecting pipe to the condenser. Start BCP and open the UG valve to establish minimum water wall flow at 30% TMCR. As the pressure is raised, first the WR and then the ZR valves will open when •separator water level increases due to boiler water swell. As pressure further •increases, the WR and ZR valves will start to close as the water level decreases. •The steam temperature at the separator inlet will reach a stable superheated •condition at app. 30% TMCR, causing the level in the separator to decrease and •eventually disappear. The boiler is now in once-through mode (dry mode). The •BCP (Boiler Circulating Pump) will be stopped automatically. •It 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 rd Feb 2009 FEEDWATER CONTROL LOOP contd.. Demand for feed water is established predominately by the Boiler Master demand. This signal, processed though a “boiler transfer function” provides the feed forward component of the total feed water demand. The “boiler transfer function” is a tunable dynamic element providing a means to dynamically match the feed water feed forward demand to actual evaporator heat transfer. Optimization of the feed forward in this manner minimizes temperature fluctuations that may otherwise result from varying dynamic response between the firing and feed water control systems (as they relate to evaporator heat transfer) thereby lessening the dependence on feedback correction. Controls of Super Critical 3 rd Feb 2009 FEEDWATER CONTROL LOOP contd.. The first controller acts on a load dependent average platen spray differential temperature. Its output represents the required adjustment to evaporator heat transfer/steam generation to maintain both the steam conditions and flue 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 differential temperature controllers output. This controller acts to adjust feed water in response to firing system disturbances and the relatively fast effect they have on separator outlet steam temperatures. The overall combined feed water feedback control action is such that feed water demand is responsive to changes in the overall unit heat transfer profile. Controls of Super Critical 3 rd Feb 2009 FEEDWATER CONTROL LOOP contd.. The combined feed forward/feedback demand signal is subject to a minimum economizer inlet flow set point (wet mode) activated if the boiler circulation pump is not in service and the unit is being fired. This ensures the minimum economizer inlet cooling flow is maintained by the feed water supply system in the event the start-up system is not available. The feed forward/feedback demand signal is subject to a second “wet mode” feed water demand developed to support separator storage tank level control. The resulting demand provides the set point to a feed 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 rd Feb 2009 THANK YOU Controls of Super Critical 3 rd Feb 2009