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Indian Institute of Technology Delhi
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ABSTRACT
In order to meet out the steam requirement, to safeguard the boiler water tubes and to safe guard the turbine
blades the boiler drum water level control plays an important role in thermal power station. The main objective
of the boiler–turbine system control is to meet the load demand of electric power while maintaining the pressure
and water level in the drum within tolerances This paper demonstrates the increase in efficiency and energy
savings by using the three element mode method of drum level control and compares it to the the traditional DP
mode .Traditionally in most power stations , the DP mode of operation is used because it is believed it provides
more robust control of the throttle valve , however throttling losses do occur .This is primarily because it is a
linear system of control . The linear system of control causes more losses and hence greater power consumption.
Three element mode reduces these throttling losses by measuring the steam level , steam rate flow as well as the
water level simultaneously , thereby resulting in a lesser loss of pressure and hence lesser demand . Pressure drop
across the throttle valve can be optimized more efficiently using this method of control and the observations and
results regarding this have been discussed .The results found were very encouraging and the method can be
applied widely to all sub critical boiler systems across the power industry .
I. INTRODUCTION
The control system for a boiler–turbine unit usually needs to meet the requirement of the amount of
water in the steam drum must be maintained at a desired level to prevent overheating of the drum or
flooding of steam lines. This is critical for the safe and economic operation of a power plant. Scoop
controller PID maintains speed of Hydraulic coupled Pump operated by constant speed motor. For Drum
Level Control, Operator gives Set point for Drum Level Value. To achieve this set point value of Drum
Level, 3 or 1 - element controller will maintain the Feed Station Control Valve position. The main
purpose of scoop control is that this will reduce the throttling loss occurring due to high fluctuating DP
across control valve. The Valve operates in better controllability position. The drum level must be
controlled to the limits specified by the boiler manufacturer. If the drum level does not stay within these
limits, there may be water carryover. If the level exceeds the limits, boiler water carryover into the
super-heater or the turbine may cause damage resulting in extensive maintenance costs or outages of
either the turbine or the boiler. If the level is low, overheating of the water wall tubes may cause tube
ruptures and serious accidents, resulting in expensive repairs, downtime, and injury or death to
personnel. A rupture or a crack most commonly occurs where the tubes connect to the drum. Providing
tight water level control in a drum is mainly accomplished by utilizing one of three types of drum level
control: single-element, two-element, or three - element. The term 'single-element' is derived from
single variable: drum level influence on the feed-water valve position. While single - element drum
II. BACKGROUND
2.1 Drum Level Measurement
HEAD
DP MODE :
Fig 7 Digitalized control and monitoring of boiler drum as seen from main control room
1 BFP - 1A 12 95 80
2 BFP - 1B 2.6 26 21
3 BFP - 2A 4.5 39 36
4 BFP - 2B 14.3 136 120
BFP hydraulic coupling’s response time and subsequent change in drum level shows that drum level
control directly through BFP scoop operation in three element mode variation is quite feasible especially
under steady operating condition
As evident from the observations above made, there is a considerable decrease in pressure drop which
was measured in full valve open condition, in the three element mode of operation. This lesser pressure
drop results in lesser demand for the BFP to work continuously at full load, thereby generating an
enormous potential for saving energy and increasing efficiency of the whole boiler operation system.
Thus, it was seen that a slight loss in control can correspond too much greater efficiency and overall a
better system of operation.
VII. CONCLUSION
A marked improvement in energy conservation and increase in overall efficiency of the system was
observed when the drum level was controlled by the three element mode, wherein the throttle valve was
fully opened as compared to the DP mode.
ACKNOWLEDGEMENTS
We are highly grateful to INDIABULLS POWER Pvt Ltd , Amravati unit for letting us use the boiler
control unit as well as the various boiler equipments in their Amravati Power Plant for our research
purposes .
REFERENCES
[1] INDIABULLS POWER Pvt Ltd , Amravati unit.
[2] Operation and maintenance manual, dong fang electric corporation ltd. Released on 2012.
[3] Invensys I/A Series hardware product specifications for controller, dong fang electric corporation ltd. Released
on 2012.
[4] M. Iacob, G.-D. Andreescu, Drum-boiler control system employing shrink and swell effect remission in
thermal power plants, Proc. 2011 3rd International Congress on Ultra Modern Telecommunications and Control
Systems and workshops (ICUMT), Budapest, Hungary, ISSN: 2157-0221, ISBN: 978-1-4577-0682-0, pp. 1-8,
Oct. 2011. IEEE
[5] M. Iacob, G.-D. Andreescu, N. Muntean, SCADA system for a central heating and power plant, (in book
chapter 8: Process Control and Automation Applications), in Instrument Engineers' Handbook Vol. 3: Process
Software andDigital Networks, 4th Edition, Eds.: B.G. Liptak, H. Eren, CRC Press, USA, ISBN: 978-
1439817766, pp. 930-939, Aug 2011
[6] Drum level control systems in process industries (Application Guide ) , ABB Power . Published 2014
[7] A guide to boiler drum level equipment control concepts by The Clark-Reliance Corporation ,16633Foltz
Industrial Parkway , Ohio ,USA.
,
[8] Xu Lian University of Nebraska-Lincoln , Optimized control strategies for a typical water loop heat pump
system , 2012
[9] Steam pressure reduction : opportunities and issues , US department of energy .
AUTHOR BIOGRAPHIES
Aditya Sindhu is a B.Tech Third year student, currently pursuing electrical and electronics
engineering from Maharaja Agrasen Institute of Technology (MAIT), under GGSIP University,
New Delhi. He has been an academic topper throughout and published a paper in an
international journal in the field of instrumentation. His research and technical interest areas
include power, transmission , instrumentation and control .
Aashish Bhaskar is working as a senior technical consultant at Indiabulls Power Ltd , a pioneer
in the name of power industry today . He is an electrical engineer and has done his B.Tech from
IIT Delhi. He has an experience of more than 5 years in the power sector and has led many teams
and project site divisions. He is singly handedly responsible for saving a lot of company’s
investment by ingenious cost cutting methods. His research areas include energy conservation
and machines