Desuperheater Temperature Control System Using Distributed Control System

International Journal on Recent and Innovation Trends in Computing and Communication
ISSN 2321 8169

587 591
Volume: 1 Issue: 7
__________________________________________________________________________
Desuperheater Temperature Control System Using Distributed Control System

(DCS)
T. Karuppiah1, Azha. Periasamy2, P. Rajkumar3, S. Muruganand4
1
M.Phil Scholar, Department of Electronics and Instrumentation, Bharathiar University, Coimbatore, TamilNadu
Assistant Professor, Department of Electronics and Instrumentation, Bharathiar University, Coimbatore, TamilNadu
3
Assistant Professor, University Science Instrumentation Centre, Madurai Kamaraj University, Madurai, TamilNadu
1
[email protected], [email protected], [email protected]
2,4
Abstract --- The Control System for Desuperheater Temperature of Boiled water is a critical task in industry. In this Paper
reviews the study and collection of measurement datas from in TNPL (Tamil Nadu Newsprint and Papers Limited) Power Plant,
there are three sections namely Deaerator tank, Boiler and Turbine. I have done this work in the turbine section. The steam from
the Boiler is at very High Temperature. The temperature of this high temperature steam is lowered by spraying the oxygen
dissolved water using Desuperheater. The spraying water is controlled by Distributed Control System (DCS). The Input to the
turbine is at High Temperature and High Pressure steam. The output of the turbine is mentioned in Mega Watts. When the
superheated steam is given to the turbine then the Temperature and Pressure output steam condition is Low. The Low level
steam is fed to the Desuperheater depends upon requirements in the various units. It is supplied to each section in TNPL.
Keywords -- Boiler, Steam, Temperature, Pressure, Desuperheater, DCS.
____________________________________________________*****_____________________________________________________
I. INTRODUCTION
The present study involves the separation of water at
various different temperatures depending on the needs. In
all the industries, water is an in-dispensable major
requirement and it is consumed in different steps. In
some industries, the water is obtained along with the
final product but at high temperature, which is of no use.
This high temperature water cannot be discharged
directly to the soil, as it will make the soil sterile. Hence,
this water should be changed to normal conditions before
discharged out. The water can also be used when it is
normal physical and chemical properties. The
Desuperheater Temperature Control System, temperature
measurement method is used to measure the temperature
of water at various points and to collect the water at
different temperatures, which can be used for several
purposes.
the arrangement of the cylindrical shaped Deaerator is

kept on the
cylindrical shaped storage tank. The
Deaerator tank has the height of 3000mm, and of its
diameter is 1800mm. The storage tank has the length of
10.5M, and of its diameter is 3M. This Deaerated tanks
level is controlled by DCS (distributed control system).
C. Water Tank Plant
Take some mineralised water from a well and insert it
in the RO plant. Here RO plant changes the fresh water
into demineralised water. Then fill the demineralised
water in feed water tank and by using feed transit pump
suck the entire demineralised from the feed water tank
and insert if into Deaerator tank.
II. DESUPERHEATER TEMPERATURE CONTROL

SYSTEM
A. Power plant
It is a specialised section, which produces electricity.
The energy produced in this section is used for almost all
the other sections in TNPL. Altogether, we have more
than 22 sections in TNPL. In order to produce electric
current, we have three important sections in power plant.
That is Deaerator Tank, Boiler and Turbine.
Figure 1.1. Power Plant Diagram
B. Deaerator Tank
Deaerated tank is used to de oxidation in the demineralized water. Deaerated tank is used to eliminate
the oxygen content in water, the size and shape of the
Deaerated tank is noted below. The Deaerated tank has
D. Function of Deaerator tank

We have two tanks in Deaerator tank (Deaerator
tank). One is at the top and the other one is at the bottom
(storage tank). By giving low steam pressure up to
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IJRITCC | JULY 2013, Available @ http://www.ijritcc.org
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ISSN 2321 8169

587 591
Volume: 1 Issue: 7
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4kg/cm, Oxygen is removed from the demineralised
water and thereby we get oxygen-dissolved water. This
process is done by adding hydrogen (chemical name),
product name Yellow card.
The oxygen-dissolved water is separated to the bottom
tank where it has been given constant inlet, outlet
pressure; temperature and level are maintained perfectly.
E. Specification of Deaerator tank
Diameter - 1800mm
Height -3000mm
Deaerator capacity 245 T/H
Steam pressure 4kg/cm
The main power system is generated in turbine output.

Let us see how electric power is generated in turbine.
High pressure and high temperature steam from the water
tube boiler is sent to turbine. What happens here is, we
all know that the turbine opens its account by means of
safts its rotation.
Here the pressurised steam is directly passed through the
turbine and by doing, so the turbine in safts are moves at
its extreme speed, there occurs EMF (Electro Magnetic
Force), and from here, we get MW (Mega Watts) power.
F. Specification of Storage tank

Volume 85 m^3
Diameter - 3M
Cylinder length 10.5 M
Water inlet 50C
Water outlet 105C
Steam temperature 185C
G. Boiler
We have two different types of boilers. They are
water tube boiler and fire tube boiler. In most cases, we
use water tube boiler because if we use fire tube boiler,
we may have to face some serious consequences.
H. Water tube boiler
By using feed pump, take the oxygen-dissolved water
and heat with high pressure. This heated water is sent to
water tube boiler by the help of feed control station and
by doing so the water is again heated with high pressure
and temperature by using coal, wood and wood powder.
In the water tube boiler, we have two arrangements,
internally i.e., top and bottom drums. Again the high
pressure is sent back to bottom drum in order to increase
the steam pressure and finally it is sent back to turbine by
the help of top drum which is inside the water tube
boiler. The water tube boiler output is at about the
pressure of 44kg/cm and the temperature is up to 440C.
In the power plant, we have five water tube boilers. The
process, which happens in the water tube boiler, is one at
the same when we come across or when we analyze the
systems in the water tube boilers. The readings from the
water tube boiler is given below.
I. Specification of water tube boiler
Capacity
= 60 t/hr
Steam High Pressure
= 44 kg/cm
Steam High Temperature = 440C
Design Pressure
= 55 kg/cm
Heating Surface
= 2874 Sq.m
J. Turbine
Figure 1.2. Power Plant Diagram
In the power plant system, we have altogether five

turbines. Each turbines produce different types of MW
power. Siemens Company manufactures turbine 1 and 2,
BHEL Company manufactures turbine 3, 4 and 5. Let us
see how many MW powers are produced in each turbine.
K. Manufacturing details
Turbine 1 = Siemens Company
Turbine 2 = Siemens Company
Turbine 3 = BHEL Company
BHEL = Bharat Heavy Electrical Ltd
L. Number of Turbines
Turbine (TG1) = 8MW
Turbine (TG2) = 18MW
Turbine (TG3) = 10.5MW
Turbine (TG4) = 24.6MW
Turbine (TG5) = 20MW
III. DESUPERHEATER TEMPERATURE CONTROL
BLOCK DIAGRAM
High Pressure [44kg/cm(440C)] steam comes from
the water tube boiler and it is sent to turbine by the help
of control valves. In turbine, we have two different
sections i.e., one starts its shaft movement from the
initial stage and the other gets its movement from the
final stage. Five different plants activate this constant
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ISSN 2321 8169
587 591
Volume: 1 Issue: 7
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Low Pressure and Medium Pressure steam by adding or
reducing its strength. For instance we have in paper
machine I and II [Paper Dry Purpose] ,Pulp Mill [Old
and New], SRP[Soda Recovery pant], Deaerator tank
etc.,.
(a) Block Diagram
(b) Control Valve Diagram
Figure 1.4. (a)Control System Method and (b) Control Valve

Diagram
(b) Valve Acual Image
Again the current which is produced here in DCS

changes into current pressure in order to activate valve.
In order to active the target level i.e., the fixed set point,
the control valve controls the DCS system until it gets its
accurate set point.
A. Steam Types
High Pressure (Temperature) = 44kg/cm(440C)
Medium Pressure (Temperature)= 11kg/cm(180C)
Low Pressure (Temperature)= 4kg/cm(160C)
Figure 1.3. Desuperheater Temperature Control
Desuperheater is used to reduce the steam temperature.

In order to reduce the steam temperature they use water
high-pressured water spray and the temperature sensor
calculates the further readings. Temperature sensor
means Thermocouples, Thermistors, RTD (Resistive
Temperature Detector), Thermopile, etc., .The
temperature output is DC mV. Again, this DC mV is
shifted to DCS (Distributed Control System) by the help
of temperature transmitter.
If we want to activate DCS, we have to apply more than
110DC voltage. The output here in DCS is (4-20 mA).
Finally, the DCS output changes its account in
accordance to the calculation given by the temperature
transmitter.
TABLE 1.1
DESUPERHEATER CONTROL VALVE OPERATIONS
Sl.
No.
PID
Process
Variable
Set Point
Output Process
Automatic
Field
Variable
Cannot be Varied
Manual
Field
Variable
Variable
CAS
Field
Cannot be Varied
Cannot be Varied
IV. DESUPERHEATER STEAM FLOW DIAGRAM

The control valve at Desuperheater temperature
control valve by giving corresponding values for I /P
converter at DCS. If we have to decide the steam, flow
temperature of the corresponding current (4 - 20mA) has
to be given to I/P by setting at DCS.
(a)Control System Method
Figure 1.5 Steam Flow Diagrams
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Volume: 1 Issue: 7
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1. Temperature Sensor
2. Temperature Transmitter
3. PID Controller
4. DA 90 Desuperheater
5. Strainer for cooling water
6. Condensate trap
7. Indication Thermometer
TABLE 1.3
PLANTS AND SET POINTS
Sl.
No
Plants
Paper
Machine I
Paper
Machine II
Old Pulp
Mill
New Pulp
Mill
Soda
Regavery
Plant
Hooking
(SRP)
Deaerator
Tank
2
TABLE 1.2
CURRENT TO PRESSURE CONVERSION
Sl.No.
Current(mA)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
4mA
5mA
6mA
7mA
8mA
9mA
10mA
11mA
12mA
13mA
14mA
15mA
16mA
17mA
18mA
19mA
20mA
Pressure(psi)
3 psi
3.75 psi
4.5 psi
5.25 psi
6 psi
6.75 psi
7.50 psi
8.25 psi
9 psi
9.75 psi
10.50 psi
11.25 psi
12 psi
12.75 psi
13.50 psi
14.25 psi
15 psi
There is a regulator to give 1.2 Kg/cm2 pressure of air

and corresponding pressure for me at I/P mingled and
tends to positioner. The positioner has the regulator of 2
Kg/cm2 pressure of air to control valve. This control
valve constructed as the type of air to open. So that air
from positioner passing to control valve, and control
valve can be opened for the corresponding air from
positioner.
The set point for I/P converter is set at the HIS (Human
Interface System). The values, which all are going to set
by DCS, are set at HIS only, and the corresponding
output values are able to see here. HIS goes to FCS
(Field Control Station). It connected with Marshalling
cabinet, which is having two cards named Analog i/p
card, Analog o/p card. Results of the process are taken
into the line of Analog i/p card and the set points to
control the process variable are taken out through Analog
o/p card. Marshalling cabinet is connected with Junction
Box.
3
4
5
6
7
Set Points
Process
Variable
LP-160C, 4kg/cm
155C - 175C
LP-160C, 4kg/cm
155C - 175C
MP-180C, 11kg/cm
175C - 185C
LP-160C, 4kg/cm
155C - 175C
MP-180C, 11kg/cm
175C - 185C
MP-180C, 4kg/cm
175C - 185C
LP-160C, 4kg/cm
155C - 175C
A. PLANT RESULTS ARE SHOWN IN THE

FOLLOWING BAR CHART
(i) SRP, SRP2 & PULP MILL
(ii) New Paper Machine, PM1 & PM2
Figure 1.5 Bar Chart
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ISSN 2321 8169
587 591
Volume: 1 Issue: 7
__________________________________________________________________________
REFERENCE
V. CONCLUSION
The project on Desuperheater Temperature Control
System is implemented in TamilNadu News Print and
Papers Limited. In Industries we cannot control the high
temperature manually. This project provides simple way
to measure the low temperature parameters. This project
is designed using Distributed Control System. The
temperature of steam flow in high temperature is
measured using thermocouple temperature sensor. In this
system, the control valve is automatically controlled and
temperature is reduced up to preset valve defined by
programmer. In future this DCS system can be updated
for more process with the same DCS programs.
ACKNOWLEDGMENTS
Our thanks to the experts who have contributed
towards development of the template.
[1] A.Nagoor Kani, Control System, First Edition.

[2] D.Patranabis, Priciples of Industrial Instrumentation, Second
Edition.
[3] Curtis Johnson, Process Control Instrumentation Technology,
Fourth Edition.
[4] R.K.Jain,Mechanical and Industrial Measurement, Sixth Edition
2003, Khanan Punlications.
[5] Johnathan. w.valvano, Embedded Microcomputer Systems, real
time interfacing-Brooks/ Cole, 2000.
[6] Rajkamal,Embedded Systems Architecture, Programming and
Design, TMH, 2008
[7] B.G. Liptak, Handbook of Instrumentation- Process Control
[8] D. E. Seborg, T. F. Edgar, and D. A. Mellichamp, Process
Dynamics and Control: John Wiley & Sons, 2004.
[9] Liptak B G, Instrumentation Engineers Handbook: Process
Control (Chilt Book Company I Radnor, Pennsylvania)1999,
705-750.
[10] Sharma S C & Gupta S, Distributed Control System and its
futures
cope,
IPPTAJ,
15
(2)
(2003)
61-65.
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International Journal on Recent and Innovation Trends in Computing and Communication

ISSN 2321 8169