Development and Application of a Dynamic Simulation Model for a Drum Type Boiler with Turbine Bypass System

W.J. Peet Babcock & Wilcox Cambridge, Ontario, Canada Presented to: International Power Engineering Conference March, 1995 Singapore T.K.P. Leung Babcock & Wilcox Cambridge, Ontario, Canada

BR-1588

Abstract
Dynamic simulation models using powerful personal digital computers are a very cost effective tool for studying the operating characteristics of power plants to improve the design and control strategy to meet stringent operational requirements. The required operating modes of large fossil fuelled generating plants call for continued operation after load rejection, and rapid, frequent and reliable unit start-ups to achieve flexible and economic production of electricity. This paper discusses the development of a dynamic simulation model and its application in the study and design of a new control philosophy and turbine bypass system to meet the operational requirements. Key Words Load rejection, temperature control.

the various starting conditions to control the rate of metal temperature change and thus to limit the thermal stresses. A turbine bypass system is one of the methods for improving start-up by allowing the boiler to build up matching steam temperature and pressure independent of the turbine. The turbine bypass system can also be used to allow the unit to continue operation after a load rejection.

Development and Validation of the Dynamic Simulation Model

The advance of the personal computer and the development of dynamic simulation language have enabled the development of economic and versatile first principles dynamic models. These models are essential for the study of control strategies to be applied to either base loaded or cycling type plants. The boiler simulated in the dynamic model is a Babcock & Wilcox Carolina style coal-fired drum type boiler utilizing a parallel downpass arrangement with biasing dampers for reheater steam temperature control. The turbine is a partial arc type high pressure cylinder with impulse stage. The maximum continuous rating of the plant is 650 MW, with the steam conditions of 170 kg/cm 2 throttle pressure, 538C superheater temperature and 538C reheat temperature. The schematic of the numerical model of the plant simulated is shown in Figures 1 and 2, for the boiler model and the balance of plant respectively, and identifies the components modelled. The major control loops modelled include the following: Drum level and feedwater flow control Coordinated boiler turbine control for firing demand and turbine governor valve demand Main steam temperature control Reheat steam temperature control HP turbine bypass system control LP turbine bypass system control

Introduction
Modern fossil fuel fired generating plants must be capable of sliding pressure operation, two-shifting, fast load ramps and continued operation under load rejection. The reasons for this requirement vary among high nuclear base load, limited interties within utility grids, flexibility, efficiency and fuel cost aspects. The response and performance of main steam temperature control is one of the important criteria determining the capability of fast load ramps to avoid thermal stress-related fatigue of high pressure and temperature components. With the steam turbine, the critical areas in regard to thermal stressing are at the admission of steam to the working parts, where high steam conditions necessitate the greatest wall and flange thickness for the casings and involve the highest temperature differentials. For two-shift units, the basic requirement is to match progressively, within certain limits, the steam temperatures with the turbine metal temperatures under

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The implementation of the plant model was performed on an IBM compatible 80486 66 MHz personal computer using PC-TRAX simulation software.[4] The thermodynamic parameters for the numerical model are set at one

equilibrium condition and the physical parameters represent all the storage terms (masses and volumes) to replicate the dynamics of the physical unit. The physical and performance data for the plant modelled were obtained from data information sheets, design data and heat balance diagrams provided by the turbine and boiler manufacturers. Model Validation There are two levels of validation for a plant model: static validation and dynamic validation. Static Validation: After proper tuning of the control loops, the dynamic simulation model can be operated in a stable steady state at various load points from 25% to 100% load. The steady state parameters at different load points obtained from the dynamic simulation model are compared with the design data from the turbine and boiler manufacturers heat balances. The outputs from the model line up very closely with the design data at 50%, 75% and 100% load with deviations of less than 1.3% in key parameters. Dynamic Validation: The simulation software supplier has performed dynamic validation for their simulation software as detailed in their technical paper[1] in conjunction with the Intermountain Power Project in Utah, USA. Agreement between the model and plant data during disturbances are generally very good. Despite the lack of field data available for this model, fuel step change and turbine valve step change open loop tests were carried out and the key parameters are shown in Figures 3 and 4. The results are consistent with the characteristics obtained in the Intermountain Power project. Tests run from 25% to 100% load at constant and sliding pressure showed that the model was stable and repeatable over this range. This shows that the equations are suitably stable to provide valid results over the range of 25% to 100% load. The model was also run to a house load condition and cold start-up condition and compared with the design data. The result was that it matched closely with the design data. Thus, the model can be used to study control system design and analysis and to assist in the development of operating procedures under different disturbances.

Figure 1 Schematic of turbine simulation model.

Figure 2 Schematic of drum boiler simulation model.

Figure 3 Fuel flow step change (100%-95%-100%) open loop response.

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MAIN STEAM PRESS

Figure 4 Turbine valve step change (100%-95%-100%) open loop response.

Steam Temperature Control

An improved main steam temperature control philosophy[2] was verified and refined with the dynamic simulation model. The control logic diagrams for this main steam temperature control and its associated boiler/turbine coordinated control are shown in Figures 5 and 6. Steam temperature control for drum-type boilers has been considered one of the most difficult loops within the boiler control system. The capability to maintain a small steam temperature deviation over wide-load ranges or during rapid load changes has limited the permissible rate of load change due to thermal stress limitations primarily associated with the turbine. The mathematical derivation of this philosophy in the reference [3] has led to a different definition of spray attemperation as follows:

Figure 5 Main steam temperature control.

FLOW/PRESS %

Figure 6 Unit coordinated control.

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 The spray attemperation is that mass flow which is equal to the difference between the actual saturated steam flow from the drum and the output steam flow derived from the total absorption in the unit. For any given equilibrium condition, the steam flow required to the turbine is known from the unit load demand, as is the fuel input. With the correct mass flow leaving the boiler, the temperature, or more precisely, the enthalpy, will also be correct. The only possible error would be due to the boiler efficiency (actual vs. assumed), the effect of which will be very small and can be compensated by controller action.

The major advantages of this concept may be summarized as follows: Variations in firing rate due to load changes are automatically included in the control since any deficiency in steam flow from the drum will provide the necessary increase in demand for spray. Variations in excess air or gas recirculation to the furnace required for reheater steam temperature control will change the steam production from the drum, and thus the spray flow demand will be compensated automatically.

Figure 7 Transient response for load ramp from 55% to 95% load at 5% per minute.

Figure 8 Transient response for load ramp from 75% to 95% at 20% per minute.

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 Variations in furnace slagging conditions which reduce steam production are automatically accounted for in the spray water controls. Upsets to the steam temperature control produced during sootblowing, or other auxiliary steam extractions, can be eliminated by providing a demand signal into the steam temperature control to account for this extraction flow. The performance of the new steam temperature control based on the mass balance approach may be demonstrated by a 5% per minute ramp rate from 55% to 95% load and a 20% per minute ramp rate from 75% to 95% load. The results are shown in Figures 7 and 8. With the dynamic simulation model, the conceptual control circuitry has been able to be simplified and enhanced so that the concept can be applied practically and reliably at site. Furthermore, the performance of the new steam temperature control may be predicted by the model. In conjunction with the new steam temperature control, a corresponding unit turbine-boiler coordinating control is required to provide reliable and accurate feedforward steam flow signal for the new steam temperature control. In selecting a signal for the feedforward to the turbine control valve, a number of possible signals were considered and studied, including unit load demand, electrical load and fuel flow signals. It was found that only the fuel flow reflects the actual heat transfer available in the furnace, and thus can provide the best index for the turbine governor valve control.

d) a relief valve for partial turbine load rejections (power/load unbalance), eliminating the operation of the ERV or spring loaded safety valves. Sizing Requirements The sizing of a turbine bypass system depends on the operational requirements of the plant and acceptability of fluid loss from the cycle through safety valves or atmospheric dump valves. There are two main areas which have to be considered to size the HP and LP turbine bypass system properly: a) Start-up Requirements: The start-up of the boiler turbine is performed in a variable pressure mode and the turbine bypass system must handle the requirements, bearing in mind that the pressure drop in steam or velocity limits for valves, piping, etc. are directly proportional to the specific volume of the steam. b) Load Rejection Requirements: The size of the bypass system depends on the magnitude of the partial load rejection which the boiler can sustain without tripping; the acceptability of fluid loss from the cycle during a load rejection, either through high pressure or intermediate pressure relief devices; and the rate at which the firing can be reduced in a stable manner. Full Load Rejection Analysis A full load rejection transient was performed on the model based on the following procedures: 1) The model was stabilized at the 100% load condition operating with the turbine bypass valves closed. 2) The generator breaker was opened to simulate the loss of export power. The house load of 25 MW remains connected to the generator. 3) The turbine governor and intercept valves closed from the power/load unbalance. 4) When the load rejection signal was detected, after a time delay of one second the following equipment operated: The fuel demand was run back to the minimum mill load for five mills (55% MCR input approximately) The HP bypass valve was commanded fast open. The IP bypass valve was operated by pressure control with a set-point of 30 kg/cm2 abs at the cold reheat inlet. The deaerator steam supply was switched from turbine extraction (IP exhaust) to cold reheat supply through a control valve with a set point of 1 kg/cm2 abs deaerator pressure. 5) The following automatic operations were executed: The steam supply to the boiler feedpump turbine drive was switched from IP exhaust extraction to main steam. The HP bypass and LP bypass spray attemperator valves operated to control the steam conditions downstream of the valves to a temperature set-point. 6) The turbine valves remained closed until the turbine/ generator speed returned to normal and then the intercept valves reopened on speed control. 7) To prevent the HP cylinder from overheating, the ventilation valve was opened to connect the HP exhaust to the condenser. This put the HP turbine under vacuum. 8) As firing rate was reduced by running back the demand of the pulverizers in service, the flow through the

HP/LP Turbine Bypass System

The arrangement of a typical turbine bypass system for a drum-type boiler unit is included in Figure 2. As shown in Figure 2, the high pressure bypass draws steam from the main steam lines, immediately before the turbine stop valves; passes it through a flow-control/pressure-reducing valve; desuperheats it to a temperature similar to that of normal HP turbine exhaust; and exhausts to the cold reheat lines adjacent to the turbine. The low-pressure bypass takes steam from the hot reheat lines at the turbine interceptor valves; passes it through pressure-reduction and desuperheating stages; and discharges to the condenser. A small auxiliary bypass ventilates the HP cylinder to the condenser, normally from a tap at the HP exhaust, upstream of the exhaust non-return valves. Fast opening of the HP bypass is provided from a contact signal, such as loss of export, load while normal opening of the HP bypass can be controlled by analog control to a steam pressure set-point. The HP bypass maintains a set upstream pressure. Similarly, the LP bypass opens on either a contact signal or reheater overpressure, and maintains a set reheater pressure. The auxiliary bypass opening is controlled by turbine speed and load to protect the HP turbine from overheating. Operational requirements of the turbine bypass system include: a) start-up and run-up of boiler b) continued boiler operation in the event of sudden load shedding or tripping of the turbine generator c) continued operation of the turbine generator at house load after sudden loss of export load without the need to lift a main steam or drum safety relief valve

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bypass system reduced permitting the HP and LP bypass valves to modulate under pressure control. 9) Condenser cooling water was maintained constant throughout the full load rejection. At the end of the load rejection, the turbine/generator was operating in a stable equilibrium condition at house load while the boiler was at 55% load with HP/LP bypass system controlling the main steam pressure to 170 kg/cm 2 and the cold reheat pipe to 30 kg/cm2 as required. The unit was then available for the operator to select any of the following: a) Hold as is, with the boiler master on hand, house load on the generator and bypass system in operation. b) Reload the turbine and resume exporting load to the grid. c) Reduce boiler load by operator action to save fuel costs. Excerpts from the results are shown in Figure 9. The results of the simulation showed that while the model was able to run to an equilibrium condition after the full load rejection, the transient response of the condenser pressure (maximum 331 mm Hg abs) exceeded the low vacuum pressure trip point of 210 mm Hg abs. Figure 10 is a plot of the heat load to the condenser versus time during the

load rejection and shows that the maximum heat load during the transient is about two times the normal heat load at the 100% load conditions. In order to maintain acceptable condenser vacuum during the transient, either the heat load to the condenser must be reduced, (i.e. a smaller turbine/bypass) or the heat removal from the condenser increased (i.e. larger condenser capacity). The dynamic model can be used to establish the criteria for either of the solutions outlined above. With the dynamic model, a proper full load rejection procedure has been developed.

Figure 10 Heat load to condenser during full load rejection.

Conclusions
The examples of an improved main steam temperature control and operation of a turbine bypass system are intended to demonstrate the value of dynamic simulation for the investigation and development of new control philosophies and enhanced operational procedures. This is particularly true for a simulation package which is user friendly and PC-based. The ability to perform transient analysis on the proposed equipment with the control algorithm prior to the finalization of the design phase assures the supplier and customer of satisfactory operation both for the hardware and the controls. References 1. Application and Validation of Dynamic Model for Intermountain Power Project by G.G. Doby, TRAX Corp.; W.R. Morgan, Intermountain Power Project. Presented in the International Conference on Power Plant and Power System Training, Simulators and Modeling, EPRI, 1991. 2. U.S. Patent No. 4,887,431 Superheater Outlet Steam Temperature Control, Inventor: W.J. Peet, Assignee: The Babcock & Wilcox Company, New Orleans, Louisiana. 3. Improved Steam Temperature Control for Drum Type Boilers in D.S.S. or Load Cycling Operation, by W.J. Peet/T. Leung, Babcock & Wilcox International, presented at the 9th CEPSI Conference, 1992. 4. Analyst Instruction Manual, TRAX Corporation.

Figure 9a Transient response of full load rejection.

Figure 9b Transient response of full load rejection.

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