MONNET POWER COMPANY LIMITED, 2X525 MW

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01. FEED WATER CONTROL (DRUM LEVEL CONTROL)
The objective of this control system is to maintain the drum level to the normal water
level of the drum at all loads. At lower loads (less than 30% MCR), the start up feed
control valve will be used as final control element and at higher loads, speed control of
Boiler Feedwater Pumps (BFPs) will be used. Drum level is measured by three
transmitters through temperature compensated constant head unit. The pressure
compensated drum level signal may be selected by Mid Value Auto Selection (MVAS)
circuit for control.
Low load: The drum level measured signal is compared with the drum level set point.
The error signal will have a proportional, integral and differential action in the single
element controller. This controller output will be the position demand signal for the start
up feed control valve. Auto/manual station is provided for auto/manual selection and
operation. Position indicator is provided for the start up feed control valve.
High load: 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
temperature compensated feed water flow signal is computed by adding feedwater flow
at economiser inlet and superheater 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. 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 desired speed signal for the individual Boiler
Feedwater Pump(BFP) speed control system. Auto/manual station is provided for
auto/manual selection and operation. Position indicator is provided for the motor driven
BFP hydraulic coupling scoop position indication and speed indicator is provided for
turbine drive BFP speed indication.
02. FURNACE DRAFT CONTROL
The main objective of the 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 or inlet damper and varying the speed of the ID fan by
variable frequency drive system. Furnace pressure is measured by three transmitters.
One signal is selected by mid value auto selection circuit for control. Excessive
furnace pressure is monitored for directional block on Induced Draft(ID) and Forced
Draft(FD) fans. Furnace pressure is compared with set point and error, will have
proportional and integral action. Fuel demand signal is added as a feed forward
feature. Master Fuel Trip(MFT) feed forward feature is provided to minimise negative
furnace pressure excursion. Separate auto/manual station, and the position indicator
for each ID fan regulating device is provided.

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To have equal loading of the ID fans each ID fan motor current (sum of channel 1 and
channel 2 current) is measured averaged and compared. The difference is used for
taking corrective action. The corrected signal is used to position the ID fan inlet
damper. 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.
Separate auto/Manual station and position/speed indicator are provided for each ID fan
regulating device(damper/VFD)
03. PRIMARY AIR HEADER PRESSURE CONTROL
The main objective of this control is to adjust the primary air header pressure according
to the feeder speed. That is, out of all the feeders, the feeder speed which is higher
than that of others is considered as set value for this control.
Primary air header pressure is measured with three transmitters. One signal is selected
by mid value auto selection circuit for control. The measured signal is compared with
the selected feeder speed signal through a high signal selector to maintain the
minimum header pressure. Deviation if any will have proportional and integral action.
Separate auto/manual station and position indicator are provided for each Primary
Air(PA) fan regulating device.
To have equal loading of two running PA fans, the PA fans motor current is measured,
averaged and compared. The difference is used for taking corrective action. The
corrective signal is used to position the PA fan regulating unit.
Refer the 'notes' in the control scheme for the interlocks.
04. MILL OUTLET TEMPERATURE AND AIR FLOW CONTROL
The objective of this control system is to adjust the mill air flow according to the feeder
speed and to maintain the mill outlet temperature at the constant set value.
Mill air flow is maintained by adjusting the hot air regulating damper while the mill outlet
temperature is maintained constant by adjusting the cold air regulating damper. The
temperature compensated mill air flow is linearised by the square root extractor. This
air flow signal is compared with variable air flow set point as a function of feeder speed.
Any error between these two signals will have proportional plus integral action. Rate of
change of fuel demand signal is added to provide feed forward feature. An
auto/manual station with position indicator is provided.
Mill outlet temperature is measured using a thermocouple with tungsten carbide
thermowell to avoid erosion. The mill outlet temperature is compared with constant set
point and error will have proportional, integral and derivative action. An auto/manual
station with position indicator, is provided.

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05. COMBUSTION CONTROL
The objective of this control is to maintain the turbine throttle pressure constant at the
desired value by adjusting the firing rate(both fuel flow and air flow).
Turbine throttle pressure is measured with primary and redundant transmitters.
Deviation, is alarmed and the controller is tripped to manual. The selected signal is
compared with the set point and any error will have proportional and integral action. A
proportional value of total steam flow and derivative of drum pressure signal are taken
as feed forward feature for the control. An auto/manual station is provided. The output
of A/M station is the air flow demand and fuel flow demand signal.
Refer the 'notes' in the control scheme for interlocks.
06. AIR FLOW CONTROL
The secondary air flow is measured at left and right side of the secondary air ducts to
wind box by means of aerofoils. Each flow will have temperature compensation. The
flow is linearised by means of square root extractors. The total PA flow measured for
each mill in service, is added to obtain total air flow to the boiler. This signal is
compared with the developed set point. 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 AH 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. High/low
limiters are used to limit the value in case the oxygen analyser is out of service. 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.
This position demand signal will be selected to the corresponding FD fans in service
through' auto/manual station. To have equal loading of FD fans the FD fan motors
current is measured. The difference is used for taking corrective action. The corrected
signal is used to position the FD fan regulating damper. Necessary interlock from
FSSS, Boiler auxiliaries interlock system Maximum Deviation Limit (MDL) etc. are
provided. Separate auto/manual station and position indicator for each FD fan
regulating device are provided.
Refer notes in the drawing for interlocks.
07. FUEL FLOW CONTROL
Fuel flow demand from combustion control and air flow signal from air flow control
corrected for fuel air ratio are compared and the lower is selected for the set point of
the fuel flow controller. (lead-lag system). This is to ensure that under any
circumstance the fuel flow should be lesser than the air flow.

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Fuel flow is measured by adding the feed signal of the feeders (or mills) in service and
the heavy oil flow corrected for calorific value. The feeder speed/rate measured signal
is hooked up to the control after a delay to suit the process lag. The actual fuel flow
signal is compared with the developed set point signal above and any deviation will
have proportional and integral action. The controller's output signal is the position
demand signal for feeder speed regulating device. Bias unit is provided to modify the
signal whenever required. An auto/manual station is provided for each feeder.
To ensure air rich furnace at all times, a maximum deviation limit system (MDL) is used.
i.e. Whenever the fuel flow is more than the air flow this will automatically reduce the
fuel flow and increase air flow to a safe value and both the air flow and fuel flow control
is transferred to manual.
Refer the 'notes' in the control scheme for interlocks.
08. AIRHEATER TEMPERATURE CONTROL
The control basically consists of the following two interrelated control systems.
A. Cold end temperature control .
B. Hot gas damper control.
SCAPH steam flow control
The purpose of this control loop is to maintain the cold end temperature above the dew
point thus preventing condensation and resultant corrosion of airheater surfaces. The
cold end temperature of AH. i.e. AH air inlet and AH flue gas outlet temperature is
measured and averaged. The average temperature is compared with the set point and
any deviation will have proportional and integral action. An auto/manual station with
position indicator is provided. The operation of this control may be required while
lighting up the boiler. The steam valves are automatically slowly closed if the measured
cold end temperature is approximately at setpoint value and the associated hot gas
damper is not fully open. This improves the overall efficiency by allowing the hot gas
damper instead of the steam valve to raise the cold end temperature when possible.
Refer the 'notes' in the control scheme for interlocks.
Hot gas damper control
This loop is used to equalise primary and secondary airheater gas outlet temperatures.
This serves to reduce gas temperature imbalances (stratification) at ID fan and
increases unit efficiency. In the automatic mode, average primary and secondary airheater gas outlet temperatures are compared and the resulting signal is received by a
PID controller. The controller output is received by two function generators, whose
output determine damper position. A limit is provided to maintain damper operator
between a specified minimum and full open position. An alarm is activated if dampers

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reach their minimum position. When a temperature difference is sensed, the
controller output will change and the damper controlling the hotter gas outlet will begin
to close while the damper controlling the colder gas outlet remain open. (see function
generator on the reference drawing) the resultant redistribution of hot gas will serve to
equalise the outlet temperatures. With this scheme one damper (that controlling the
colder outlet) will always be fully open while the other damper modulates between its
minimum and full open position. In manual control, dampers are to be initialised by the
operator at 100 % open position. A signal indicating that both dampers are fully open
is to be interlocked into the ID fan start logic as a start permissive. Transfers are
designed to be bumpless. If control power is lost dampers are to lock in position or to
be forced fully open.
Refer notes in control scheme for interlocks.
09. SUPERHEATER/REHEATER STEAM TEMPERATURE CONTROL
General
Steam temperature control is provided by a combination of burner nozzle tilt positioning
and Superheater(SH), Reheater(RH) de-superheating spray. Steam temperature is
maintained by allowing nozzle tilt to respond to the lower of either SH or RH outlet
temperature, with spray responding to the higher. Auto manual stations are to be
provided for modulating the following
1

SH spray water valve - left

SH spray water valve - right

RH spray water valve - left

RH spray water valve - right

Burner tilt power cylinder.

Each measurement is manually selectable between a primary and redundant element.

Each pair of elements is compared and excessive deviation between the primary and
redundant is alarmed, with control transferred to manual.
SH spray water valve control
In the automatic mode, each SH spray water valve is controlled by a cascade control.
Under normal conditions average SH outlet temperature (Tsho), the primary controlled
variable, is in the outer loop of the cascade control for each valve;
SH
Desuperheater(DESH) outlet temperature (Tshdso), an index of the immediate effect of
spray valve operation, is in the inner loop. The outer loop PID controller receives an
error signal equal to the average deviation of Tsho set point and each measured final

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SH (left and right) outlet temperature (Tshol and Tshor). The Tsho set point is
programmed as a function of unit steam flow for constant pressure operation (or sliding
pressure operation). The outer loop controller establishes a set point for the SH DESH
outlet temp. This set point is compared to measured Tshdso and the resulting error is
used to position the SH spray valves.
If the deviation between Tsho set point and measured Tshol or Tshor exceeds a preset
high limit, control of the outer cascade loops is transferred from average Tsho to the
individual final SH outlet temperature, Tshoa and Tshob. Strong feed forward to the SH
temperature control which interact with each other are provided. These feed forwards
are needed to compensate for over firing and under firing which may be required
initially. When changing unit load, feedforward signals are utilised as follows (using unit
load increase as an example):
1. The rate of change of fuel demand increase (an indication of over firing) is used to
open the SH spray valves to counter the initial temperature rise.
2. Drum pressure and steam flow (applied inversely) to spray valve demand) and tilt
position (applied directly) are used as an index to recognize the tendency for temp. to
drop after item-1 above occurs, and is used to close the SH spray valves to counter the
subsequent temperature drop.
Interlocks are provided to close the SH spray valves at loads less than 20% MCR.
RH spray water valve control
In the automatic mode, each RH DESH spray water valve is controlled by a cascade
control. Under normal operating conditions RH outlet temperature (Trho), the primary
controlled variable, is in the outer loop of each cascade control; RH DESH outlet
temperature (Trhdso), an index of the immediate effect of spray valve operation, is in
the inner loop.
The outer loop PID controller receives an error signal final RH (left and right) outlet
temperature (Trhol and Trhor). The Trho set point is programmed against the main
steam flow curve, for constant pressure operation (or sliding pressure operation). The
outer loop controller output is modified with tilt position to establish a set point for the
RH DESH outlet temperature. This set point is compared to measured Trhdso, and the
resulting error is used to position the associated RH DESH spray water valve.
If the deviation between the Trho set point and the individual measured final RH outlet
temperature exceeds a preset high limit, control of the outer cascade loops is
transferred from average Trho to the individual measured final RH outlet temperature
(Trhol and Trhor) to allow spraying of the hot lead.
Interlocks are provided to keep the spray valves closed at loads less than 20% MCR.

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Nozzle tilt control
The average Tsho and Trho error signals are compared and the greater of the two
errors (i.e., the lower of the two temperatures) is selected for nozzle tilt control. An
interlock is provided to keep the tilts at their base (horizontal) position at loads less than
25% MCR. If any spray water valve opens fully, the tilt control is interlocked to disallow
further raising of the tilts, and thus prevent possible over heating of the SH and RH
outlet lead.
Refer notes in control scheme for interlocks.
10. LIGHT OIL FLOW CONTROL
Light oil flow is regulated by maintaining the pressure at the header. Two pressure
transmitters are used to measure the pressure and the healthy signal is applied to the
controller where it is compared with the set point. The error signal will have
proportional & integral action in the controller. The controller output is the position
demand signal for light oil pressure control valve.
11. HEAVY OIL FLOW CONTROL
Heavy oil flow is regulated by maintaining the pressure at the header. Two pressure
transmitters are used to measure the pressure and the healthy signal is applied to the
controller where it is compared with the set point. The error signal will have proportional
& integral action in the controller. The controller output is the position demand signal for
heavy fuel oil pressure control valve. One motorized inching bypass valve is provided.
When the main valve is not in operation the bypass valve can be manually operated.
12. ATOMISING STEAM PRESSURE CONTROL
Atomising steam pressure is controlled by maintaining the pressure at the header. Two
pressure transmitters are used to measure the pressure and the healthy signal is
applied to the controller where it is compared with the set point. The error signal will
have proportional & integral action in the controller. The controller output is the position
demand signal for the Atomising steam pressure control valve.
13. LIGHT OIL PRESSURE CONTROL (PUMP HOUSE)
Light oil pump outlet pressure is measured and compared with the setpoint. The
deviation is subjected to proportional and integral action. The output of the controller
is used to position the Light oil pump outlet pressure control valve to maintain the
pressure at the set value.
14. HEAVY OIL PRESSURE CONTROL (PUMP HOUSE)

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Heavy oil heater outlet pressure is measured and compared with the setpoint. The
deviation is subjected to proportional and integral action. The output of the controller
is used to position the Heavy oil pressure control valve to maintain the pressure at
the set value.
15. HEAVY OIL TEMPERATURE CONTROL (PUMP HOUSE)
Heavy oil heater outlet temperature is measured and compared with the setpoint.
The deviation is subjected to proportional and integral action. The output of the
controller is used to position the HFO temperature control valve to maintain the
temperature at the set value.

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