THERMAL Doc. No.

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SYSTEM Sheet No: 1 of 12

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THREE ELEMENT DRUM LEVEL CONTROL

(This document should be read in conjunction with Drawing No. (W828-00-95-72-3-002)

PURPOSE:

The purpose of drum level control is to maintain constant level in the steam drum by
controlling feed water flow (FCV 01).

MEASURED VARIABLES:

i) Drum level is measured by two numbers of level transmitters (LT-01 & LT-02)
ii) Drum pressure is measured by drum pressure transmitter (PT-02).
iii) The feed water flow is sensed by measuring the differential pressure across the orifice
Using differential pressure transmitter (FT-01).
iv) Feed line pressure is measured by pressure transmitter (PT-01).
v) Feed line temperature is measured by temperature element (TE-01)
vi) Steam pressure is measured by pressure transmitter (PT-03).
vii) Steam temperature is measured by the thermocouple (TE-05) and temperature
transmitter (TT-01).
viii) Steam flow is sensed by measuring the differential pressure across the flow nozzle
using a differential pressure transmitter (FT-02).

CONTROL PHILOSOPHY:

For normal operation signal from two level transmitters are averaged and used as control
input signals. In case of failure of any one of two level signals the other input is taken for
control. Here 1 out of 2 logic is followed from drum level controls. The averaged signal
received by level controller is processed in a PI controller and an output is generated.

The level transmitter signal are compensated with drum pressure signal and compared
with manual set point provided.

i) The steam flow signal is compensated by steam pressure and temperature

Signal.
ii) The compensated steam flow signal is then routed to summator block.
iii) The second signal to the summator block is the outputs of level control PI
block.
iv) The feed water flow is compensated by feed line pressure and temperature
Signal
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SYSTEM Sheet No: 2 of 12

v) The output of the compensation block is given as cascaded set point to feed water flow
Controller.

vi) Another input to the feed water flow controller is compensated feed flow
Signal.
vii) The output signal from step (vi) is connected to A/M block and the mode can
be selected as auto (or) manual accordingly.
The A/M block output is connected to I/P converter of the control valve.
viii) Position feedback of feed control valve is taken to DCS.
viii). The I/P convertor converts the current signal into pneumatic signal and
Regulates the feed control valve at required position.
ix). Manual operation of feed control valve is also possible via DCS.
x). Position feed back indication of feed control valve (ZT-01) is also available
in DCS.
xi). Drum level very high and very low signals are taken from DCS and they are
Used for tripping the ID, FD&PA fans.

COMBUSTION CONTROL

(This document should be read in conjunction with Drawing No. (W828-00-95-72-3-003)

Combustion control means that the total amount of air being delivered into the furnace at
any instant matches proportionally to the total amount of fuel entering that furnace at that
particular time. Theoretically perfect combustion of a fuel requires the provision of
exactly the right amount of air needed for complete combustion of the fuel.

PURPOSE OF COMBUSTION CONTROL

Too much of air inside the furnace leads to excess air and losses in efficiency and too low
amount of air leads to improper combustion and even leads to formation of localized
clinkers.

Hence combustion control is basically divided into two parts:

a) Air flow control

b) Fuel flow control

AIR FLOW CONTROL

MEASURED VARIABLES

01. The air flow is measured through one air flow transmitter located across the
aerofoil (FT-03)
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SYSTEM Sheet No: 3 of 12

02. The steam flow is measured in the main steam line through steam flow transmitter
(FT-02)

GENERAL POINTS ON AIR FLOW CONTROL

01. Normally during boiler startup combustion control should not be in line.

02. During shutdown combustion control will be effective.

03. For combustion control to be in auto mode, five compartments should be in

operation.

04. The airflow Vs steam flow curve for this boiler is enclosed along with this write-
up. From this curve, we can read the minimum and maximum air flow for each
compartment.

For Example :
Maximum airflow required when two compartments are in operation (Max.2) =37.13
TPH.
Maximum airflow required when two compartments are in operation (Min1.2) =25 TPH.

LET US CONSIDER ALL 5 COMPARTMENTS ARE IN OPERATION.

A. When the airflow signal received from airflow transmitter is within the designed
limits (ie. MIN-5 & MAX-5), then DCS should perform the action as explained in
control philosophy.

B. The DCS should generate high airflow alarm and low airflow alarm, when
maximum and minimum flow are attained respectively in that number of
compartments in operation.

We shall consider high airflow (MAX-5 is reached. You are requested to

consider 5% margin over the limits provided by us. This margin shall be fixed at
site. The DCS should generate an alarm as explained above stating that “Steam
drawal is more or check the fuel compositions” and the total air flow is brought to
stable condition temporarily by DCS

This high airflow depends on the following:

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SYSTEM Sheet No: 4 of 12

When all the five compartments are in operation there will be an airflow, which
corresponds to designed steam flow for specific steam temperature and pressure.
This airflow is the maximum airflow of the boiler.

This maximum airflow depends upon the following.

a. Steam flow to the turbine.

b. Fuel composition.

The stable conditions mentioned we require the maximum air for the design
conditions of rated load of boiler. Normally these stable conditions are given
temporarily to alert / inform operator that the boiler reaches the max. air flow.
Always there is a possibility of exceeding this condition due to sudden /
momentary steam drawn for a shorter period or due to the variations of fuel
compositions than the designed conditions. Hence this will give an indication to
operator that, why a higher flow of air is taking place.

Now we shall consider that low air flow is reached (Min-5) the DCS should
generate an alarm stating that “Steam drawal is less – shut down any one
compartment”. Now the following cut-off logics should be done automatically by
DCS.

A signal should trip fuel feeder of that particular compartment and consequently a
signal to close the respective air line damper.

Now the boiler will be operating with 4 compartments and 1 compartment will be
in shutdown.

C. Let us consider any three compartments are in operation.

i) When high air flow alarm is reached the DCS should generate an alarm stating
that “STEAM DRAWAL is increased – Introduce non-operating compartment
into operation”.
Now the following cut-in logic should be done through DCS manually.

ii) Vth compartment FD air line damper should be opened.

iii) Ensure PA air line damper of that particular compartment is opened.

iv) Vth compartment fuel feeder should be started. The fuel feeder should be
started only when the bad temperature of the compartment is above 600°C.

Now five compartments will be in operation.

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SYSTEM Sheet No: 5 of 12

v) When low air flow is reached (Min-5), the DCS should work as explained for
shutting that compartment.

CONTROL PHILOSOPHY

The DCS should perform the following operations.

a) The no. of compartments in operation should be checked first.

b) We shall consider 4 compartments are in operation.
c) Now (Min-4) will be the set point to the controller.
d) The DCS should now see the steam flow value.
e) The airflow value, corresponding to this steam flow value is taken from the look-
up table and this airflow will be the set point to the controller now.

f) Based on this airflow set point the FD suction will be opened / closed.

g) The output from DCS should be suitably routed through the A/M blocks available
in DCS, so as to enable auto / manual operation.

Thus the airflow set point value will vary from MIN-5 to MAX-5 depending upon
the steam flow value.

FUEL FLOW CONTROL

MEASURED VARIABLES:

01. The main steam line pressure is measured by using the pressure
Transmitters (PT-03)

02. Bed temperature of all compartments is measured by bed

Thermocouples ((TE-07A-TE-07D) TO (TE-11-A- TE-11D))

Normally we are providing 4 nos. of thermocouples in one compartment –i.e.two

at the bottom of the bed and two at the top of the bed. So there will be 4 nos. of
bed thermocouple per compartment and a total 20 nos. for the boiler.

This bed thermocouple is the main criteria for boiler operation. So DCS should
be capable of sensing this, bed temperature signals accurately and following
logics should be done.
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SYSTEM Sheet No: 6 of 12

Since we have considered 4 nos. of thermocouples per compartment, the average

of these 4 nos. Should be considered as bed temperature.

Any erratic signal of thermocouple shall be discarded automatically. Erratic

signal shall be any one of the following:

a) During running when any of the thermocouple showing temperature below 600°C
should be discarded when compared to other thermocouples showing reading in
the range of 800-900°C.

b) Open circuit in thermocouple

c) If the temperature difference between the thermocouples are greater /

Lesser than 50°C.

The following are various temperature zones, defined in our FBC Boiler by
considering the average bad temperature as defined before.

01. NORMAL BED TEMPERATURE

The average bed temperature in the range of 850°C to 900°C is defined as the
normal bed temperature.

02. LOW BED TEMPERATURE

The average bed temperature in the range of 800°C to 850°C is defined as the low
bed temperature.

03. HIGH BED TEMPERATURE

The average bed temperature in the range of 900°C to 960°C is defined as the
high bed temperature.

04. VERY HIGH BED TEMPERATURE

The average bed temperature above 960°C is defined as very high bed
temperature.

The DCS shall also have some dead band (between 10°C and 20°C) between the
two temperature zones. The dead band shall be applicable for decreasing trend
only. (i.e. From very high temperature zone to high temperature zone).
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SYSTEM Sheet No: 7 of 12

CONTROL PHILOSOPHY

In fuel flow control the speed of the fuel feeders are controlled based on the steam
line pressure and by considering the bed temperature.

The main steam line of the boiler is measured by a pressure transmitter.

WHEN BOILER IS IN OPERATION :

The pressure transmitter located at main steam line of the boiler should be
considered. When main steam line pressure is decreased the fuel feeder speed
should be increased and when steam line pressure is increased, the fuel feeder
speed should be decreased.

i) NORMAL BED TEMPERATURE

When the bed temperature is normal, the DCS should give output based on the
difference in steam pressure signal.

The output should go to all the running fuel feeders parallelly so as to decrease or
increase the fuel feeder speed.

ii) LOW BED TEMPERATURE

When the bed temperature is low, the DCS should first bring the temperature to
normal. This is achieved by incrementing the fuel feed speed (i.e. Original fuel
feeder speed + some incremental value). The DCS shall have provision for time
gap (in terms of minutes) between one increment and the next increment of fuel
feed speed. The actual time will be decided after commissioning the boiler. The
4-20 mA output from fuel feeder VFD will be taken into DCS and the same
should be calibrated to VFD speed. Normally the incremental value can be 10%
to start with and provision shall be available in DCS to change the same in future.
Once the bed temperature comes to normal zone, the DCS should work based on
the steam pressure signal.

iii) HIGH BED TEMPERATURE

When the bed temperature is high, the DCS should first bring the temperature to
normal. This is achieved by decrementing the fuel feed speed (i.e. Original fuel
feeder speed – some decremental value). The decremental value can be 10% to
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SYSTEM Sheet No: 8 of 12

start with and provision shall be available in DCS to change the same in future.
The DCS shall have provision for time gap (in terms of minutes) between one
decrement and the next decrement of fuel speed. The actual time will be decided
after commissioning the boiler. Once the bed temperature comes to normal zone,
the DCS should work based on the steam pressure signal.

iv) VERY HIGH BED TEMPERATURE

The fuel feeder of that particular compartment should be tripped. Once the
temperature comes to below 850°C, then fuel feeder can be switched ON.

GENERAL POINTS ON FUEL FLOW CONTROL

1. DCS shall have provision for the following.

a) The combustion control loop should be passed during the boiler start-up.

b) For combustion control to be in auto mode minimum two compartments should be

in operation.

c) The current output of the fuel feed controllers should be within the specified
limits. The upper limit of the current output is fixed by the maximum speed
corresponding to the maximum carrying capacity, moisture content and calorific
value. The maximum speed of the fuel feeders will be about 10% more than the
normal speed required at full load when all the compartments are in operation.
The upper and lower limits of the current output will be informed during
commissioning and should be possible to change the values at site based on the
operating conditions.

2. Speed of fuel feeders can be manually operated from VFD panel also.

3. Even though the steam pressure is low, the fuel feed speed can be increased till
the bed temperature is in normal zone. When the bed temperature reaches 960°C
the fuel feeder speed shall not be increased.

FURNACE DRAUGHT CONTROL

This document should be read in conjunction with Drawing No. (W828 –00-95-72-3-004)
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SYSTEM Sheet No: 9 of 12

PURPOSE:

To maintain the furnace draft constant at the desired value for all the boiler loads. This is
achieved by changing the flow of flue gas by throtting the RPC of the ID fan controlling
the speed of motors.

MEASURED VARIABLES:

01. The furnace draught is measured by using draft transmitters (DT-06).

CONTROL PHILOSOPHY:

a. The current output from the furnace pressure transmitter (DT-06) is feed to the
PIC in the DCS. This is compared with the set point in DCS and the output from
DCS varies accordingly.
b. The output signal from the PIC in the DCS is feed to ID fan RPC through
Auto/Manual selector block provided in PIC and mode can be selected as auto or
manual accordingly.
c. The A/M block output is connected to I/P converter/VFD.
d. Position feed back of ID fan RPC (ZT-07) is taken to DCS.
e. The I/P converter converts the current signal in to the pneumatic signal and it
regulates the RPC at required position.
f. When the furnace pressure increases the RPC of ID fan opens and when the
furnace pressure decrease the RPC of ID fan closes and then maintains the
furnace pressure as a constant value.

DEAERATOR PRESSURE CONTROL:

(This document should be read in conjunction with Drawing No (W828-00-95-72-3-005)

PURPOSE:

To maintain constant deaerator pressure.

MEASURED VARIABLES:

a) Deaerator storage tank pressure is measured using a pressure transmitter (PT-04).

CONTROL PHILOSOPHY:
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SYSTEM Sheet No: 10 of 12

a) De-aerator Pressure signal is fed to the analog input card.

b) The processor performs PI action on the input signal.
c) The output signal from step (b) is connected to A/M block and the mode can be
selected as auto (or) manual accordingly. The A/M block output is connected to
I/P convertor.

d) Position feedback of deaerator pressure control valve is taken to DCS and

displayed in CRT.

e) When the deaerator pressure increases, the pressure control valve closes, and
when the deaerator pressure decreases, the control valve opens and thus steam
enters the deaerator, so as to maintain the constant pressure.

DEAERATOR LEVEL CONTROL:

(This document should be read in conjunction with Drawing No: W828- 00-95-72-3-006)

PURPOSE:

To maintain constant deaerator level.

MEASURED VARIABLES:

a. Deaerator storage tank level is measured using a level transmitter (LT-03).

CONTROL PHILOSOPHY:

a. Daerator level signal is fed to the analog input card.

b. The processor performs PI action on the input signal.
c. The output signal from step (b) is connected to A/M block and the mode can be
selected as auto (or) manual accordingly. The A/M block output is connected to
I/P converter.

d. Position feedback of deaerator level control valve is taken to DCS and displayed
in CRT.

e. When the deaerator level increases, the DCS should give a signal to close the
level control valve and when the water level decreases, the DCS should give a
signal to open the level control valve.
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SYSTEM Sheet No: 11 of 12

SOOT BLOWING STEAM PRESSURE CONTROL:

(This document should be read in conjunction with Drawing No.W828-00-95-72-3-009)

PURPOSE:

Soot blower steam pressure shall be maintained by regulating control valve on steam line
show that soot blowing is carried out at design pressure.

MEASURED VARIABLES:

a) Steam pressure shall be measured through a pressure transmitter (PT-05). This

measured value shall be compared with desired set level in the PI controller,
whose output shall modulate the pressure control valve in the steam line to soot
blower.

CONTROL PHILOSOPHY:

a) Pressure transmitter signal is fed to the analog input card.

b) The processor performs PI action on the input signal.
c) The output signal from step (b) is connected to A/M block.

d) The A/M block output is connected to I/P convertor (ZY-08)

e) When the pressure increases, the pressure control valve closes, and when the
pressure decreases, the pressure control valve open and thus maintains the
pressure.

AUTOMATIC BED ASH COLLING CONTROL:

(This document should be read in conjunction with its Drawing No: W828– 00-95-01-4-
011)

PURPOSE:

To cool the hot ash to be specified temperature before discharging.

MEASURED VARIABLES:
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SYSTEM Sheet No: 12 of 12

Air box draught transmitter senses the high ash level in the compartment.

Each compartment ash drain in connected with individual bed ash coolers. Any
compartment’s bed ash level can be controlled independently with the help of solenoid
operated power cylinder provided.

CONTROL PHILOSOPHY:

The ash level high signal from any one of the compartment shall initiate the bed ash
cooling. The bed ash cooling shall be either auto or manual.

AUTO MODE:

The DCS should be programmed in such that if any one of compartments draught
transmitter is high, the control circuit will energize the solenoid operated power cylinder
of that particular compartment. This compartment should be opened for a pre-set time.
When the time is elapsed the compartment should be closed. Now the DCS should check
for the high ash level. It still the ash level is high the next compartment should be opened
and this should be continued. It ash level is low, the sequence shall be stopped. Care
should be taken such that the compartment, which is not running, is not opened.

MANUAL MODE:

The operator by visualizing the high alarm signal can open the compartment.

NOTE:

When any tow air box draught transmitters show high signal at a time; then the DCS
should first consider tag no of the compartment showing higher pressure.