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Boiler-Tuning Basics, Part I
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Boiler-Tuning Basics, Part I
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Menu Follow Us search ‘oficial Pubtication of FE] CONNECTEDPLANT inep:snwn.connectedplantconference.com/?utm.source-powersutm_medlum=headeriog @eneray es acon IEEE ge comecint spartan neta Ome (ps umwcalsriburedenengyconference.com REGISTER NOW (/WEBINARS/MOBILE-WATER-TREATMENT/) to participate in this webinar: The role of mobile water treatment to offset ‘emergency or scheduled plant shutdowns Home (hetps://www.pewermag.com) | Instrumentation & Controls (hetps://mww.powermag.com/category/instrumentation-controls/) | Soler-Tuning Basics, Part Boiler-Tuning Basics, Part I 03/01/2008 | Tim Leopold Save to myPOWER ‘on my first project as @ combustion control engineer, I was responsible for loop checks and for watching the experts tune the system controls The first loop I tried bothered to mention to me that the proper time span to tune drum level control to is 20 to 30 minutes. 1 also zoomed in on the drum level, which hhas a normal range of #15 inches, though my trend range was #3 inches. Finally | did not know that drum level can be a very "noisy" signal, so the hours I spent trying to tune out that noise were wasted, ‘the drum level contro, At that time the trend-tune program defaulted to @2-minute windew, and ne one Eventually, got the bright idea to add alittle derivative to the loop control. In the time it took to program 0.01 as the derivative gain and then immediately remove it, the bolle tripped. Thus began my career in boller tuning, In the 20-plus years since my inauspicious debut, I've had the opportunity to successfully tune hundreds of bolers, new and ald, that needed either a contral loop tweak or a complete overhaul Many inexperienced engineers and technicians approach boller tuning with a heavy hand and litle insight into the inner workings of individual control loops, how highly interconnected they are with other loops in the boiler system, or what change should be expected from the physical equipment the loops are to central. My purpose in writing this article is to explore these fundamentals and share my experiences, Itrust these insights will be of value to the power industry and specifically to thase who want to tune boilers for rock-solid stability yet agility when responding to process changes. What Constitutes Good Control? Every boiler ever built has its own set of peculiarities. Even two boilers built at the same plant atthe same time to the same drawings will have Unique quirks and special tuning issues. I begin with a description of the various boiler and subsystem control loops before moving to good boiler-tuning practices that are sufficiently robust to accommodate even rinute differences between what should be identical boilers. From a pure controls perspective, the most important goal is to tune for repeatability ofa value, not the actual va itself, We do not care that there are exactly 352,576.5 poh of fuel going into the furnace; we orly care that, for a given fuel master demand, we get the same amount every time, There will be process variation, of course, but the goal isto tune the controls to keep that varlation as smalls possible and then tune for accuracy. Boiler control processes are where Iwill begin. Additional control functions outside the furnace will be explored in Part in a future issue of POWER.Operator Controls The operator's window into the control system is referred to as a master or as a hand]auto station, control station, or operator station. The station is the operator interface to a given control loop and is typically a switch located on the control panel in older plants or accessible from the ‘operator's keyboard in those equipped with all-digital controls, Typically, the control station allows the operator to move between manual and automatic modes of operation. All ofthe control loops discussed inthis article combine to form the set of controls that manage the key boiler operating functions, When a control loop is placed in manual mode, the operator will have direct control of the output. In automatic mode the output is modulated by the proportional-integral-lerivative (PID) controller. In automatic mode the operator usually has some contrel aver the set point or operating point ofthe process, either directly or through the use of a bias signal. Occasionally, 2s in primary airflow control, the set points displayed either ‘on the controler located on the control panel or on the computer screen graphic display, Cascade made is @ subset of the automatic mode in Which the operator turns over control of the set point to the master, whose internal logic generates the set point, Usually, there is some digital logic that requires the station to be interlocked to manual, as well as control output tracking and set point tracking, Furnace Pressure Control Furnace pressure cantralis 2 fairly simple loop, butit’s also one that has important safety implications. The National Fire Protection Associat (NFPA) codes, such as NFPA 85: Boller and Combustion Systems Hazards Code, are dedicated to fire and furnace explosion and implosion protection. Before you begin tuning a boiler, you must read and understand the NFPA codes that apply to your boiler. Balanced draft boilers use induced draft (1D) fans andjor their inlet dampers to control boller furnace pressure. The typical control system has ‘one contraller that compares the difference between the furnace pressure and the furnace pressure set point that uses a feedforward signal usually based on forced draft (FD) fan master output. The output from the controller typically is fed thraugh an ID fan master control station, ‘Smaller units may have a single ID fan, but larger units usually have two or more ID fans. The most! have seen is eight IO fans fora single unt. In this case, the output from the control loop or master's distributed to the individual fan contro st The NFPA also requires some additional logic forthe furnace pressure control loop to ensure adequate operating safety margins. There should bbe high and low furnace pressure logic to block the ID fan from increasing or decreasing speed, as is appropriate, For example, because ths fan sucks flue gas out of the furnace, on a high furnace pressure signal the fan should be blocked from decreasing speed and on a low furnace pressure signal should be blocked from increasing speed. On a very negative furnace pressure signal, there should be an override that closes the ID inlet damper or decreases 1D fan speed, The settings of these signals are determined by the boiler and fan supper during the design of the plant. Also, on a main fuel trip (MFT) there should be MFT kicker logic. An MFT occurs when the burner management system detects a dangerous condition and shuts down the boiler by securing the fuel per NFPA and boiler manufacturer requirements. When fuel is removed, the flame within the furnace collapses violently, which can cause a lot of wear and tear on the boiler and related boiler equipment. It also presents the very real danger of an implosion, The MFT kicker should immediately reduce the control autput tothe fan(s) proportional ta the load being carried at the time of the MFT and then release the device back to normal operation. Lam constantly amazed at how well furnace pressure can be controlled, especially when you consider the amount of fuel and air being injected Into a ball of fire many stories tall and the ferocious and chaotic environment inside a boller. The fac that a well-tuned system can maintain furnace pressure to - 0.5 inches HO is remarkable. Atypical mistake made by boilers tuners i the use of very fast integral action to the furnace pressure controller. Furnace pressure changes quickly, Bu not instantaneously, so consider the size of your furnace and the amount of duct work between the furnace and the fans as capacitance in the system, because air s compressible. recommend restraint when tuning furnace pressure when comes to adding integ «gain. Interestingly, the feedforward for almost every boiler ison the order of O¥ to 100% in, and 0% to 80% out The trends in the following figures show what you should expect to see from your furnace pressure control. The plant from which these data were taken uses both fan inlet damper position and fan speed to control furnace pressure. Figure 1 illustrates an 1D fan tuning trend and the reaction ofthe ID fans and the furnace pressure to a change in set point.Unit and 2 damper demand 5] eumace pressure set pont Unit and2fan speed demand 1D tenbias 1. Blowing hot air. Induced draft fans are used to control furnace pressure and primary combustion airflow. In this test, induced draft fan and Percent furnace pressure respons to a step increase in furnace pressure set point. Source: Tim Leopold Airflow and Oxygen Trim Forced draft fans are typically placed in automatic after the 1D fan master s placed in automatic. Usvally, the FO fan master is only controlling airflow; however, some boilers are designed with secondary airflow dampers that control the airflow. In this case the FD fan will control the secondary air duct pressure to the dampers (Figure 2) lime aio ie Total airflow ormzd ind case os inte Ei oo (0; time air tow iB ine 2. Favorite trend. I typically monitor airflow, Op content inthe flue gas, and furnace pressure control when I tune airflow. The particular response of those variables was observed after a20%6 load increase in coordinated control mode. Source: im Leopold Alr and, consequently, 0, control are critical to the safe and efficient operation ofa bolle. The airflow signal is normally measured in terms of a percentage and is usually not available in volumetric or mass flow units, The obvious question is, "Percentage of what?" The answer is the percentage of airflow that s available from a given fan or system of fans. The actual measured pounds per hour of air does not matter, because airis free, and the final arbiter of proper airflow isthe O2 content in the flue gas (gases leaving the furnace), Because of variations in coal heat content, air temperature, and combustion conditions inside a bolle, we ensure proper burning by measuring the amount of oxygen content in the flue gas, commonly referred to simply as 0. Pulverized coal has an interesting property: Under certain conditions of heat in a low-oxygen atmosphere, coal can self'ignite or even exalade, ‘Therefore, personnel safety and equipment protection require boller operators to maintain excess O; In the flue gas, The amount of excess 0, Is determined by the load on the plant and the type and design of boiler. Typically, the load signal used Is steam flow. In any coal-fired boiler, airflow demand isa function of the boller firing rate or boiler demand (Figure 3). Gas- and oilfred boilers have lower O, requirements at higher loads.3. Extra air is a good thing. Atypical 0, set point curve fora coal-fired plant isa function of boller firing rate or boller demand, Minimum levels of alr are required so that reducing conditions in the furnace never accur. Source: Tim Leopold The term cross-limiting refers to the function of fuel flow that limits the decrease in alr demand and the function of airflow that limits the Increase in fuel demand, When decreasing load, the air demand follows its lag function and the fuel demand follows the boiler demand to ensure that there is always more air than fuel going into a furnace so explosive conditions never develop inside the furnace. When increasing load, the ‘opposite is true, Ths is truly an elegant piece of logic. The output from the boller master isthe boiler demand, Cross-limited air demand is developed by choosing the highest of four calculates values: boiler demand function, the lag of the boiler demand signal, a minimum value (per the boiler manufacturer under the NFPA codes), and a function ofthe actual fuel flow. The crasslimited fuel demand is selected from the least of three signals: boler demand function, a lag of boiler demand, and a function of actual airflow. When load is increased, air demand follows the function of the beller demand and the fuel demand follows its lag ofthe boiler demand To develop the air demand for your boller, hold your 0; trim controller in manual at $0% output, At alow, medium, and high oad, place your FD fan master, or secondary airflow dampers ifthe boilers So equipped), and your fuel master in manual. Then manipulate the airflow until you {ind the amount that satisfies your ©, set point requirement, using stack opacity as a realty check on the O set point. Next, manipulate the airflow characterization curve as required to allow the air dernand to equal or slightly exceed the fuel flow or boller demand. Record the airflow required for that fuel flow and then move on to another fuel flow setting. Three points should be sufficient for a good airflow curve. Typically, the airflow measurement isa diferental pressure taken in alr ductwork and requires 3 square root in order to make it near, Ensure that your signal also temperature-compensated. Each boller should have an airflow characterization curve that should be a virtual straight line, If isn't, would be concerned about unexplained “correction factors” or “magic numbers” that should not be necessary. Next, the characterized airflow is multiplied against a function ofthe 0 trim controller. The O, trim control loop uses the set point curve, discussed above, plus an operator bias to calculate an ©, set point for various loads. This set point is compared with the O, content of the ue {gas used by the control system. Its best to have several O» measurements because of striations or variations of temperature and oxygen that are present across the stack cross-section. Different plants use different measurement schemes, selecting the average, the median, or the lowest measurement to control, 3 trim is designed to be a steady state trim ofthe airflow. Ifyou, or your tuner, are trying to control airflow with the trim controller, stop It, The Oy trim controller should be mostly integral action with very litle proportional and ne derivative gain. Your time is better spent reworking your air demand curves or airflow characterization than attempting to tune the airflow using the O; controls ‘The output from the O, trim control station then goes through a function generator such that a 0% to 100% input signal equals a 0.8 te 1.2 output signal. This value is then multiplied against the characterized airflow. This means that the O3 trim controller can adjust the airflow 420%. In some ‘extreme cases this amount can be varied, but for most boilers 220% is more than sufficient. The final result is a signal referred to as "Os trimmed sirflow." This value is then used by the airflow controller to modulate the ID fans or dampers, Because 0, trim cantral uses a primarily integral-only controler, it does not have the dynamic capabilties of most controllers. As a result, there are times when the controller should not be allowed the full range of control. At low loads, typically less than 30% to 35%, output from the Op trim controller should not be allowed to go below 50% but should be limited to some minimum setting se that an airtich atmosphere is always ‘maintained in the furnace. ‘Also, when the lag function In the cross-Imited air demand is driving air demand, airflow will lag behind. That i, the air will remain elevated for a period of time as the load, and the fuel flow, decreases. As 2 result, oxygen in the flue gas will spike up. Ifthe 03 trim controller is not limited, the controls would see the 0, go higher than the set point and start cranking, cranking, cranking down, Then, when the load gets ta where the‘operators have set it and the fuel flow Is no longer decreasing, airflow demand wil catch up with the boller demand, and the Q, will quickly begin 10 fall. The controller will see the 0 > falling and begin to crank up. But because there is very lite, or no, proportional gain, it wil take a long time to bring the air back. This can result in an unsafe or, atthe least, a nerve-wracking condition. The NFPA requires some additional logic forthe airlow control loop, There should be high and low furnace pressure logic to block the alrflow {from inereasing or decreasing, as is appropriate, Because this fan forces air into the furnace, on high furnace pressure, the fan should be blocked {rom increasing speed; on a law furnace pressure signal, i should be blacked from decreasing ‘Also, on an MET there are NEPA and boller manufacturer requirements that must be considered. One important consideration is the need to hold the air in place for a time after an MFT or ifthe airflow should drop very low during or just after a trip. The dampers should go to a full open position shortly after the loss ofall FD or ID fans (providing 2 natural draft air path). Moreover, in the typical boiler air control system, ifthe 1D fan is placed in manual, then the FD fan fs normaly forced to manval. Ifthe FD fan is in manual, then 02 trimis forced to manual, Drum Level and Feedwater Control Feedwater Is fed into the drum in a typical subcritical pulverized coal-fired drum boller via elther a serles of valves in parallel wth a series of constant-pressure feedwater pumps or a battery of variable-speed feedwater pumps. Ifthe feedwater level in the drum goes too high, wat become entrained in the steam going to the turbine and can cause catastrophic results. Ifthe drum feedwater level goes too low, the drum itself can become averheated, possibly resulting in catastrophe. Feedwater (and drum level} control has two modes of automatic operation: single- and three-element control, The drum level set point for both modes is set by the operator. In single-element contral the difference between the drum level and the drum level set point provides the error signal that is used by the single-element controller to contral the rate of water entering the drum by modulating the feedwater flow control valve. Three-element contrel governs the three varlables, or elements, feedwater flow. re used in this control scheme: drum level steam flow, and Drum level control uses a cascaded controller scheme consisting of an outer and an inner controller. Steam flow is an incication of the rate at Which water is being removed from the drum. A function of steam flow is used as a feedforward to the outer controller. The drum level error is ‘then operated on by the outer controller, The output ofthis controller isthe feedwater flow set paint. The difference between this set point and the feedwater flow is then operated on by the inner controller, The output from this controller is then used to modulate the feedwater flow Three-element control is much more stable and robust than single-elerment control. The reason that we use single-element control at all has to do with the nature of the instrumentation. Typically, feedwater flow, and occasionally steam flow, Is developed by using a flow-measuring device like an orifice plate ora flow nozzle, where flow rate is proportional to differential pressure. However, a problem occurs at low flow rates (low boiler load), where diferential pressures are nat as solidly proportional as we would like and therefore untrustworthy for boiler control Consequently, singleelement control s used at low loads. ‘Awelltuned drum level cantral can be placed in automatic as soon as a pump is started, By the time steam flow has passed 25% of the total range, we can consider steam flow signals to be reliable. That's a good point at which to switch Co three-element contol There really is not much in the way of manual interlocks or control tracking when it comes to the drum level loop. Ifthe drum level signal or the feedwater flow valve control output goes out of range, oF no pump Is running, this station Is normally locke ‘manual mode. That's about it. Normally, tuning for the single-element controller consists of big proportional and very small integral gain settings. Tuning for the three-element controller has some additional requirements, Asin any cascaded loop, itis absolutely crucial that the inner controller be tuned as tightly as time ill slow. The inner controller, the feedwater controller in this case, must have an Integral action that is faster than that of the outer, or drum level, controller (Figure 4). This is true forall cascade loops.‘Steam Yow feed fenward Feeva tou stp Percent Tire [ninites) Bole doraya pprepn: Briar sat point 7. * Time ines) 4. Rapid responder. A typical coal-fire boiler with a properly tuned deur level control will respond very quickly to a substantial load increase (op) orload decrease (bottom), The dynamic response of other key variables in boller drum level control system is also llustrated, Source: Tim Leopold You may notice that as the load decreases, che drum level sags downward, and as the load increases, the drum level is slightly elevated. This ‘means that the steam flow feedforward isjusta tad too strong. A minute adjustment to the feedforward signal can add stability to the control loop (Figure 5). Brier domed Stam fo as foodforward Feadwate ow set pint Percent ~~ Foodhtater master dara ime mirates) 5. Small i big. A small increase in the feedforward signal added more stability tothe drum level contrals, Only very small incremental changes In feedforward should be made when tuning drum level controls. Source: Tim Leopold ‘Superheat Temperature Control Superheated steam temperature control is very straightforward. Normally, steam leaves the drum and travels through a primary superheater(s) before entering the desuperheater, where attemperating water is mixed withthe stearn to modulate its temperature before it enters the next superheater section. After the steam passes through that superheater, the outlet temperature is measured Ifthe inlet cemperature tothe superheater is a measured variable, the preferred method of control isa cascaded loop. In this case the outer controller uses the superheater autlet temperature as the process variable, The output from the outer controllers the inlet temperature set point. The output from the inner controller is spray water demand. Ifthe supetheater outlet temperature isthe only avalable measurement,then we are forced to use a single-element control loop. In either case, it's Important that the controls are equipped with a feedforward signal variety of signals can be used for the superheater temperature control feedforward. Usually, the boiler demand is a good starting point for the ‘feedforward because this signal anticipates the measured temperature signals. My experience is that the boiler demand usually has a well defined relationship with the superheater temperature, ‘Other measured variables are available to supply the feedforward signal, Throttle pressure is usually used in tandem with the throttle pressure set point as an indication of over- or underfiring ofthe boiler, but throttle pressure is transient In nature. Allow versus fuel flow or stearn flow ‘may be used in the same way. The ratio of fuel flow to the top mill versus the other mils isa good indicator ofthe changing dynamics in the boiler, especially ithe boiler is large and has many burner levels, In this case itis @ good rule of thumb to think of the top elevations as affecting ‘temperature more than pressure, and the lower elevations as affecting steam pressure more than temperature. Finally, the reheater temperature control affects the superheater temperature to a greater or lesser degree, depending on the type of boiler manufacturer and its method of control ‘The feedforward signal development may include both static and dynamic functionality The static cases are basically a function of the variable that you are using. Dynamic feedforward refers to a derivative kick based on the movement of the chosen variable. For example, the ratio of airflow to steam flow might be used as an indicator ofthe boiler’s movernent up or down, and the feedforward then can be manipulated accordingly. Patienceis virtue when tuning these feedforwards, because steam temperature processes may have long time constants. Deaerator Level Control It is often possible to use a three- element controler for deaerator level control, Whereas the drum level controls use drum level, steam flow, and feedwater flow, the three-element controller for the deaerator uses deaerator level, feedwater flow, and condensate flow. It is usually nat necessary to provide adaptive tuning for this control loop, but do add it f possible. Reheat Temperature Control Itis an interesting fact that superheater spray adds to the efficiency of a unit but reheater spray flow decreases the unit's efficiency, Maximum boiler efficiency is always the goal, so boller manufacturers have developed alternative approaches to contral reheat steam temperature, Babcock & Wilcox uses a gas recirculation fan to move flue gas from the outlet of the boller back into the furnace, elther directly or through the secondary air wind box. More recirculation yields higher furnace temperature and, therefore, higher steam temperatures. Combustion Engineering, now Alston Power, is famous for its tangential, titing burner design that can move the furnace fireball vertically to control stearn temperat -es, Foster Wheeler boilers use a superheat/reheat gas bypass damper to shunt flue gas to the appropriate gas pass ducts to control reheat temperature, Spray valves are also used in each design, although the reheat temperature set point to the spray valve controller is usually several degrees higher to keep the reheater spray to a minimum. The setup far the reheat temperature spray valve contral isthe same as that forthe superheat temperature contral:twe valves (modulating valve and block valve) an attemperator or desuperheater, and a reheater section. However, reheat steam temperature control is notnormally a cascaded loop. Assuming that the primary method of control (gas recirculating fan, tiking burners, or bypass damper) is operating, the sprays {are held in reserve. The operator-adjustable set point is used directly by the primary control mechanism. A sliding bias is added to the set point before itis sent to the spray controller, Usually the spray set point is set higher than the primary reheat temperature control set point before the sprays are enabled, to reduce the reheater spray flow. Part If willlook at fuel flow control, pulverizer air control, and overall plant control options such as boiler- and turbine-following modes and plant coordinated contral Timm Leopold (tim
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(¢+String fromcharCode(116,105,109,46,108,101,111,112,111,108,100,64,104,111,116,109,97,105,108,46,99,111,108)+"7")} sa feld service engineer \with ABB and has more than 20 years’ experience tuning controls on power plants around the world. His book You Can Tune a Boiler But You Cantt Tuna Fish i sated for publication in March,myPOWER FEATURES Why a Single Source Is Best for Chemical-Feed Systems (https://www.powermag.com/why-a-single-source- best-for-chemical-feed-systems/?mypower) What isthe best way to construct a complete chemicaHeed system for use Read More © (heps:/weew.powertnag,com/whyra-single-source-ts-best- for-chemicalfeed-systems/?mypower) FEATURES Debate Continues: Can New Technology Save Nuclear Power? (https://www.powermag.com/debate- continues-can-new-technology-save-nuclear-power/? mypower) Nuslear power provides carbone electrcly for a warming worl. Butis se sl practic Read More © (https: weew_powermag,com/debate-continues-can-rew- technology-save-nuclear-power/?mypower) 1Comment —Powermag © Recommend @ Soin the ciscussion = Loa nem ‘on sion ur wi oisaus @ Name @) stints ere = AY + Reply - Share» Besvoscrve © ass Heretaee ef QB FEED, (re The book tie, arp off of a great REO Speedwagon album from the 1970's imy dashboard (tos engage powermag.com/content/home? rrypower) rersunes Mercury Remediation System Reduces Contamination in Power Plant Wastewater (httpsi/ www powermag.com/mercury-remediation- system-reduces-contamination-in-power-plant- wastewater/?mypower) Anew tem em aslo) mercy, long woh ater ‘cana fom power plan ead More © (psu powermag.com/mercury-erned ation system reduces cortaminationin-power-plantwastewater/?mypower rower How Digital Technology 1s Changing Power Plants (https://www.powermag.com/how-digital-technology- is-changing-power-plants/2mypower) Digital technolaay i everywhere today including nm Computer hardware and software ae. ower plants, Read More © (netps|/wwn.power changing-power-slants/2mypower) s/now-digital- technology. @ Login Sort by Bost shame. uso yoursttond Disgusads G@ Disqus’ Privacy PoloyPrivacy PolloPrveey jobs powermag.comijobsecker/search/resuls/}MUNICIPAL ENERGY SERVICES AGENCY 4J08 DESCRIPTION - AMERICAN. MUNICIPAL POWER, INC. - Columbus, on (https:/[jobs.powermag,com/job/municipal- cenergy-services-agency job- ddescription/45769105/2669/) Utility Engineer- Genoa Charter Township - Brighton, MI (hteps:/Jjabs.powermag.com/job/utility- ‘engineer/46010208/2665/) Faclities Electrical Engineer (mid. el) LOCKHEED MARTIN ‘CORPORATION - Kennedy Space Center, FL (heeps:/[jobs.powermag,com/job/facilities- lectrical-engineer-mid-career: level/45974618/2669/) Search Jos ost aon Sees es etercaaeagy ironic Fes seagowermss
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