PRESENTATION ON

“AUTO CONTROL
LOOP SYSTEM”

PREPARED BY-
Rajeev Singh
Shekhawat
C & I Department 1
 INDEX

 INTRODUCTION OF CONTROL SYSTEM

 AUTO CONTROL LOOP SYSTEM
 TYPE OF CONTROL ACTION
 PID CONTROLLER
 PID TUNING
 AIR FLOW CONTROL
 LIMITATION OF PID CONTROLLER
 FEED FORWARD CONTROL
 FURNACE PRESSURE CONTROL
 CASCADE CONTROL
 DRUM LEVEL CONTROL

2
cont...
CONTROL SYSTEM
A Control System is a set of Electronic devices that
regulates the behaviour of other systems.
Control system are used in industrial production for
controlling equipment or machines.
Control System is depends upon measuring
instrumentation in power plant ,which are based on:-

Temperature sensing element (SH TEMP CONTROL)

Pressure Transmitter (FURNACE DRAFT CONTROL)
Level Transmitter (DRUM LEVEL CONTROL)
Flow Transmitter (AIR FLOW CONTROL)

3
cont...
There are two types of control system-

 OPEN LOOP CONTROL SYSTEM :

In open loop control system, controller output is
generated based on inputs without monitoring
feedback.

 CLOSED LOOP CONTROL SYSTEM:

In closed loop control system, controller output is
taken into consideration and corrections are made
based on feedback. A closed loop system is also
called a feedback control system.

4
cont...
BLOCK DIAGRAM OF CONTROL SYSTEM

5
cont...
AUTO CONTROL LOOP SYSTEM
When talking about automatic control theory
certain standard terms are used.
BASIC AUTOMATIC CONTROL TERMS:-

PROCESS VALUE
DESIRED VALUE(SET POINT)
MEASURED VALUE(FEEDBACK VALUE)
DEVIATION (ERROR)
ERROR= SET POINT (SP) - PROCESS VALUE (PV)
CONTROLLER

6
cont...
 SET CONTROLLE
POINT ERROR R OUTPUT
(SP)

PROCESS VALUE
(PV)

7
cont...
TYPES OF CONTROL ACTION
PROPORTIONAL ACTION :
The Proportional controller output is directly
proportional to the change in the error. If there is no process change,
there is no change in output from the controller.
Controller output= Gain value(P) set from DCS X Error(e)
INTEGRAL ACTION (RESET):
Integral controller is provided to eliminate the
offset that resultant from the proportional controller. Integral action is a
function of both time and magnitude of deviation. Reset action continues
as long as there is a difference between the set point and process value.
DERIVATIVE ACTION (RATE):
The Derivative action is directly related to how
fast the process changes. Derivative action is the advanced action of
the proportional controller. Derivative acts at the start of the process
change, when the process change its rate.
We used these above control actions as per process requirement. The
combination of all control actions is called a PID Controller.
8
cont...
PID CONTROLLER

A Proportional–Integral–Derivative controller (PID controller) is a

control loop feedback mechanism commonly used in industrial
control systems. A PID controller continuously calculates an error
value e(t) as the difference between a desired set point and a
measured process variable.
ERROR= SET POINT-PROCESS VALUE
cont... 9
FUNCTION OF PID CONTROLLER

To reduce errors by automatically adjusting the systems input.

To improve stability of an unstable system.

To increase or reduce the system’s sensitivity.

To enhance robustness against external disturbances to the

process.

To produce a reliable performance.

10
cont...
WHAT IS PID TUNING?

Tuning is adjustment of control parameters to

the optimum values for the desired control
response. Stability is a basic requirement.
However, different systems have different
behavior, different applications have different
requirements, and requirements may conflict
with one another.

11
cont...
MATHEMATICAL EXPRESSION OF PID CONTROLLER

Where,
Kp - Proportional gain, Ki - Integral gain
Kd - Derivative gain, r(t) - Set point
e(t) - Error, u(t) - Control output
y(t) -Measured value

12
cont...
As a PID controller relies only on the measured
process variable, not on knowledge of the underlying
process. By tuning the three parameters of the
model, a PID controller can deal with specific process
requirements.

Final controller output is calculated as-

13
cont...
 PID TUNING FOR PROCESS

SET POINT

Amplitud
e

PROCESS VALUE

Time
14
cont...
BOILER AUTO LOOP CONTROL
FURNACE PRESSURE CONTROL
PA HEADER PRESSURE CONTROL
DRUM LEVEL CONTROL
AIR FLOW CONTROL
FUEL FLOW CONTROL
BFP SCOOP CONTROL
SH TEMPRATURE CONTROL
RH TEMPRATURE CONTROL
LDO FLOW CONTROL
LDO PRESSURE CONTROL
HFO FLOW CONTROL
HFO PRESSURE CONTROL
HFO TEMPRATURE CONTROL
BURNER TILT CONTROL
ATOMISING STEAM PRESSURE CONTROL
MILL AIR FLOW CONTROL
MILL TEMPRATURE CONTROL
CBD LEVEL CONTROL

15
cont...
TURBINE AUTO LOOP CONTROL
CO-ORDINATED MASTER CONTROL (CMC)
DEAREATOR LEVEL CONTROL
DEAREATOR PRESSURE CONTROL
HOTWELL LEVEL CONTROL
HPH-5 LEVEL CONTROL
HPH-6 LEVEL CONTROL
LPH-2 LEVEL CONTROL
LPH-3 LEVEL CONTROL
CEP MINIMUM RECIRULATION CONTROL
GLAND SEALING PRESSURE CONTROL

16
cont...
AIR FLOW CONTROL
PURPOSE:
The purpose of this loop is to maintain the airflow
required for combustion at the desired value by regulating the
blade pitch control of FD fans A & B.

EXECUTION:
The secondary airflow is measured at left (2
nos. of flow transmitter) and right (2 nos. of flow transmitter)
side of the secondary air ducts to wind box by means of
aerofoils. Each flow will have temperature compensation. The
flow is calculated by means of square root of differential
pressure across the aerofoil.

17
cont...
AIR FLOW TRANSMITTERS

FLOW
TRANMITTERS

HP SIDE

LP SIDE

ISOLATINS
VALVE

EQUALISING
VALVE

PRESSURE
TRANSMITTER

LEFT SIDE

RIGHT SIDE
18
cont...
DATA SHEET OF SECONDARY AIR FLOW ELEMENT

19
cont...
PRIMARY AIR FLOW

The Primary Air flow for each mill in service is measured by

venturi flow element across the PA mixed air duct.
Summation of all the primary air flow of individual mill is the
total primary air flow to the boiler. We have installed 2 nos.
of primary air flow transmitter with the range of 0-110
mmwc , which is converted into 0-90 TPH at DCS-end.
The total air flow required for the
combustion in boiler is the summation of total secondary
air flow and total primary air flow.

Total Air Flow = Secondary Air Flow + Primary Air Flow

20
cont...
DATA SHEET OF PRIMARY AIR FLOW ELEMENT

21
cont...
 22
cont...
The air flow demand from coordinated control and actual fuel
flow whichever is high (lead lag system) is selected to ensure
enriched combustion air. The oxygen in the flue gas at the inlet
of APH is measured as primary or redundant.
Transfer switch can be selected for either average
value or individual value. This signal is compared with excess
air set point and any error will have proportional and integral
action to have better combustion efficiency.
Under any circumstance the air flow should not be less
than 30% MCR flow. This signal is the developed set point and
the air flow signal will have proportional and integral action in
the air flow controller.

23
cont...
LIMITATIONS OF PID CONTROL
While PID controllers are applicable to many control
problems, and often perform satisfactorily without any
improvements. The fundamental difficulty with PID
control is that it is a feedback control system, with
constant parameters, and no direct knowledge of the
process, and thus overall performance is reactive and a
compromise.
Now PID controller introduced itself in the two
categories:-

Feed-forward control

Cascade control

24
cont...
FEED-FORWARD CONTROL

The control system performance can be improved by

combining the feedback control of a PID controller with
feed-forward control. Knowledge about the system can be
fed forward and combined with the PID output to improve
the overall system performance. Feed forward can be
based on the set point and on extra measured
disturbances.
We can understand Feed-forward Control
system through example of Furnace Draft control.

25
cont...
FURNACE DRAFT CONTROL

PURPOSE:

The main objective of this control is to

maintain the furnace pressure constant at the desired
set value at all loads. This is achieved by changing the
flow of flue gas by modulating the inlet guide vane and
varying the speed of the ID fan by VFD system.

26
cont...
EXECUTION:
Furnace pressure is measured by three
transmitters. One signal is selected by mid value auto selection
circuit for control. Furnace pressure is compared with set point
and actual value. Generated deviation will have proportional
and integral action.
Fuel demand signal is added as a feed forward
feature. Feed-Forward feature is provided to minimise negative
furnace pressure.
The ID fan inlet damper positions between a
maximum and a minimum position limit for optimised control
action. If ID fan position goes outside these limits, an error
signal goes to a controller, whose output is used to vary fan
speed to bring back the inlet damper within the set limits.

27
cont...
AIR FLOW FUEL FLOW

28
cont...
 29
cont...
CASCADE CONTROL

One additional advantage of PID controllers is that

two PID controllers can be used together for better
dynamic performance. This is called cascaded
PID control. In cascade control there are two PIDs
arranged with one PID controlling the set point of
another.

Now we discuss the Cascade control loop

with the help of Drum Level control.

30
cont...
DRUM LEVEL CONTROL
PURPOSE:
Boiler drum level is kept constant under all load conditions. For loads
more than 30% control system acts on three elements control which utilizing
steam flow, feed water flow and drum level. Under low load conditions, drum
level is maintained by single element.
Execution:
At lower loads (less than 30% BMCR), the start up feed control
valve(FD-20) will be used as final control element and at higher loads, full load
control valve (FD-14/17) will be used. If the full load control valve is taken for
maintenance, stand by feed control valve will be used.

SINGLE ELEMENT CONTROL

•DRUM LEVEL

THREE ELEMENT CONTROL

1.DRUM LEVEL

2.STEAM FLOW

3.FEED WATER FLOW

31
cont...
SINGLE ELEMENT CONTROL

The Drum level measured signal is compared with the

drum level set point. The error signal will have a PI
Controller.
The PI controller output will be the position
demand signal for the 30% control valve to maintain the
normal drum level. Auto/manual selection block is provided
for operation.

32
cont...
 33
cont...
THREE ELEMENT CONTROL
At higher loads the start up control valve shall be closed. The
steam flow shall be measured. In order to prevent sudden
response due to drum swell and shrink on load change, a time lag
unit shall be included in the steam flow signal. The compensated
feed water flow signal is computed by subtracting feed water flow
at economiser inlet to Re-heater spray water flow.

The error signal produced between drum

level measured signal and drum level set point shall have
proportional, integral and differential action in the three element
drum level controller.

34
cont...
This will be added with steam flow signal which is the feed
water flow demand signal (set point for feed water flow). This
will be compared with the feed water flow in the feed water
controller. Deviation if any will have a proportional and integral
action in the feed water controller.

This controller output will be the position

demand signal for the full load feed control valve.

Auto/manual selection is provided for operation.

35
cont...
 36
cont...
 37
cont...
PUT CONTROL LOOP IN AUTO
Desk engineers must follow the following
parameters-
1. Deviation between set point and process value is
minimum as possible.
2. Put the loop in auto under steady state condition.

38
cont...
CHANGEOVER OF LOOP FROM AUTO TO MANUAL MODE:

The auto loop shall be trip to manual under the following conditions-
1. in case of two nos. of transmitter fail the auto loop trip to manual.
2. If both transmitter is healthy but deviation is high (±10%).
3. If median is selected two transmitters fail.
4. Operator shall be able to put loop again in auto with 3 rd transmitter
selection through OWS.
5. In case of three transmitter median is selected and one of the tranmitter
fails the average of other two healthy transmitters is given as output to the
PID controller.
6. If all the three transmitters fail.
7. Failure of transmitter are alarmed in each of the above cases on OWS.
8. The supervision of final control element shall be provided, in case there is
deviation between demand and control element it is alarmed on OWS after
the time delay(10 sec).
9. All auto loops, Auto to Manual changeover alarm has provided on LVS.

39
cont...
TROUBLESHOOTING AND
MAINTENANCE
Now we understood, the main parameters of Auto
Control System-
Measure
Compare
Compute
Correct
These four functions are completed by these elements:
Controller , Final control element i.e. Control valve and
position feedback Transmitters.

In auto control system measuring element and Final

control element play a key role to controlling the
process with in limit.
40
cont...
MEASUREMENT DEVICES

S.NO. PROCESS TYPE SENSOR

1. TEMPERATURE THERMO COUPLE(T/C) & RTDs
2. PRESSURE PRESSURE /DIFFERENTIAL PRESSURE
(DP)
3. FLOW FLOW TRAMSMITTERS
4. LEVEL LEVEL TRAMSMITTERS

Final control element i.e. control valve, blade pitch

control , IGVs, Hot air dampers , Cold Air dampers etc
must be regulate in proper manner.

41
cont...
FINAL CONTROL ELEMENT

FROM DCS

4-20MA
0.2 – 1 KG/CM2 POSITION
POSITION
4 – 5 KG/CM2 FEEDBACK
FEEDBACK
TRANSMITTER
TRANSMITTER

4-20MA

TO DCS
42
cont...
 FEED STATION CONTROL VALVE
I/P- A “current to
pressure “ transducer
(I/P) converts an analog ALR-To lock existing air in
signal i.e. 4-20 ma into case of supply failure.
pneumatic output i.e. 3- I/P
15 psi (0.2-1 kg/cm2)” CONVERT AIR LOCK RELAY
ER
VOLUME
OPERATING BOOSTER
PRESSURE
REGULATOR

POSITIONER SUPPLY PRESSURE

REGULATOR

HAND WHEEL
LIMIT SWITCH
BOX

POSITION
FEEDBACK
TRANSMITTER
PFT- convert control valve
movement in electrical
signal i.e. 4-20 ma.
43
cont...
CALIBRATION OF CONTROL VALVE

44
cont...
TEMPERATURE MEASUREMENT

TEMPERATURE BATH-
To calibrate thermocouple temperature
element

45
cont...
PRESSURE MEASUREMENT
MANOMETER-
To calibrate Differential type
pressure and
flow transmitter.

HART CALIBRATOR
46
cont...
THANKS
47