1.0 1.1.0 1.1.

MODULATING CONTROL OIL CONTROL LSHS FLOW CONTROL The LSHS flow control is designed to maintain the proper flow to oil burners satisfying the boiler demand; the control philosophy is based on simple feedback closed control loop limited by the output signal of LSHS pressure at burners control loop. A low selecting logic compares the boiler firing rate demand signal, generated by Unit Coordinator logic (see ref.[9]), to the total boiler combustion air flow signal (measured at RAHs outlet, upstream the common header), the lowest of then. Deducted by coal flow (if any), via another low selecting logic, is compared to the secondary air (S.A.) flow to oil burners signal, the lowest of them becomes the total oil flow demand, common to LSHS and LDO control loops; the result is that total fuel demand is limited to the level of the signal representing available total air flow and that oil flow set point is limited to the level of the signal representing available secondary air flow to oil burners. The total oil flow demand, deducted by LDO flow signal, become the set point of the LSHS flow controller, that is compared to its flow measurement and through a dedicated controller sets the demand for the LSHS control valve. To avoid that flame to active burners can be due to LSHS low pressure, i.e. control valve too much closed, a high selecting logic compares the output signal of flow controller to the output signal of pressure controller, the highest of them becomes the actual position demand for the LSHS flow control valve. The loop will be forced manual if no burner is in service with LSHS or if one the other fuel masters (LDO-coal) is in automatic mode. As soon as the LSHS main trip valve opens, the control valve will be forced to fixed open position until the first LSHS burner is in operation and then the LSHS flow control loop will be released to auto mode. For boiler trip the total oil flow demand is forced to zero value and thus the LSHS control valve will close.

1.102

ATOMIZING STEAMPRESSURE CONTROL The atomizing steam pressure control is a simple feedback closed control loop, designed to maintain a steam constant pressure to oil burners to allow a good combustion. The set point is computed as a function of burner load and is manipulated by the operator via a biasing capability. The set point is compared to atomizing steam pressure value and through the controller sets the demand for the related control valve.

1.1.03

LDO FLOW CONTROL

The LDO flow control is designed to maintain the proper flow to oil burners satisfying the boiler demand; the control philosophy is based on simple feedback closed control loop limited by the output signal of LDO pressure at burners control loop. The total oil flow demand, generated as explained ins 1.1.01, deducted by LSHS flow signal, becomes the set point of the LDO flow controller, that is compared to its flow measurement and through a dedicated controller sets the demand for the LDO control valve. To avoid that flame to active burners can be lost due to LDO low pressure, i.e. control valve too much closed, a high selecting logic compares the output signal of flow controller to the output signal of pressure controller, the highest of them becomes the actual position demand for the LDO flow control valve. The loop will be forced to manual if no burner is in service with LDO or if one the other fuel masters (LSHS coal) is in automatic mode. As soon as the LDO main trip valve opens, the control valve will be forced to fixed open position until the first LDO burner is in operation and then the LDO flow control loop will be released to auto mode. For boiler trip the total oil flow demand is forced to zero value and thus the LDO control valve will close. 1.2.0 1.2.1 AIR CONTROL SECONDARY AIR TO OIL BURNERS FLOW CONTROL The S.A. to oil burners flow control is designed to maintain the proper flow to oil burners satisfying the boiler demand, the control philosophy is a simple feedback closed control loop. A high selecting logic compares the boiler firing rate demand signal, generated by Unit Coordinator logic (see ref,[9]), deducted by coal flow (if any), to the total oil flow signal, the highest of them becomes the S.A. to lit oil burners flow demand; the result is that S.A. flow demand is limited to (not lower than) the level of the signal representing available oil flow. The resulting signal is increased by the cooling air flow to the idle burners; the result is the S.A. to oil burners set-point, that is compared to the flow measurement and, through the dedicated controller, sets the S.A. total flow demand for all the oil burners in service. Because each oil burner is equipped with its S.A. control damper, the S.A. flow demand is limited according to the number of burners in service and then multiplied by 8 (total number of oil burners) and finally divided by the number of oil burners in service; consequently the gain of the total loop doesnt depend on the number of burners in service.

Proper firing action are performed according to the request from Burners Management System and Air & Flue Gases functional groups that force oil burners S.A. control dampers at proper position, that are: Minimum position for cooling; it means that, when related burner is out of service, the damper will be almost quite closed Partially open (approx. 30%) to guarantee minimum combustion air flow rate to perform furnace purge sequence. Last position for five minutes if the combustion air flow is below the purge rate at the time of the trip, waiting time for purge Fully open for natural draft requirement. One of each burner, i.e. eight, slave control loops are provided, receiving the same flow demand from the unique master loop. Each slave loop is provided with independent biasing capability by the operator. 1.2.2 AIR MASTER CONTROL The combustion air master control is designed to maintain the air flow in its proper relationship with fuel for good combustion conditions. A high selecting logic compares the boiler firing rate demand signal. Generated by Unit Coordinator logic (see ref. [9]), multiplied by the output signal of O 2 controller (see 1.1.03) in order to with the right amount of combustion air, to the total fuel (coal plus oil) flow signal; the highest of them, compared, via a high selecting logic, to a fixed value to provide a minimum combustion air flow capability by preventing the air flow set point from being reduced below 25% of full range (25% is minimum air flow as per NFPA code) becomes the set point of the air master controller; the result is the actual fuels flow sets the minimum air flow demand. The output signal of the air master control station (i.e. combustion excess air demand) corrects the set point of each secondary plus tertiary air flow control (see 1.3.07); if all of them are in manual mode, the air master is forced to manual too. 1.2.3 OXYGEN CONTENT CONTROL If only the amount of theoretical air were furnished some fuel would not burn, therefore to assure a complete combustion additional combustion air has to be furnished; the additional amount of combustion air is called excess air, and it is evaluated by the oxygen percentage not used that leaves the boiler in the flue gases. So the oxygen trim control loop is used to calibrate continuously the combustion air flow demand; the O2 percentage set point is a function of the boiler load (SH steam flow) and the operator has a biasing capability to shift the O 2 percentage set point curve up or down of the established curve based on boiler test. The O2 percentage set point is compared to the analyzer output signal and through a dedicated controller sets the oxygen percentage correction, that is sent to the air

master. In order to avoid wind-up, the integral action is blocked if the air master is in manual mode. At the output of the oxygen trimming control high and low limits are provided. 1.2.4 MULLS SEALING AIR PRESSURE CONTROL The hot sealing air to mills pressure control is designed to maintain the pressure at mills seals within the operating range. The hot sealing air to mills pressure set point, based on boiler load (SH steam flow) is compared to header pressure value and through the controller sets the demand for the related control damper; the control is based on simple feedback closed loop. The operator has a biasing capability to shift the hot sealing air pressure set point curve up or down of the established curve based on boiler test. Two of the above control loops are provided, one for each three mills. 1.3.00 1.3.1 MILL CONTROL COAL MASTER CONTROL This control loop is devoted develop the total coal demand. A low selecting logic compares the boiler firing rate demand signal, generated by Unit Coordinator logic (see ref. [9]), to the total boiler combustion air flow signal (measured at RAHs outlet, upstream the common header) the lowest of them, deducted by total oil flow (if any), becomes the set point of the coal master controller; the result is that total fuel demand is limited to the level of the signal representing available total air flow. The coal demand is compared to the total coal flow measurements and through a dedicated controller sets the demand for all mills (coal total demand), i.e. the output signal of the coal master control station. The coal total demand is limited by total mills capability, a signal taking into account: The number of mills available to the master (i.e. in service and in automatic mode); the mills in service with one feeder are considered with half capability The coal rate to the mills in manual and loading.

When no mill is available to the master, the coal total demand tracks the capability, i.e. the coal rate to the mills in a manual.

In order to obtain the coal demand to each mill (see 1.3.02), the (limited) coal total demand is multiplied by 4 (because the MCR can be achieved by 4 mills at full load); the resulting signal is subtracted by the coal rate to the mills in manual and then ratioed by the number of mills available to the master; the result is that the again of the total loop does nor depend on the number of mills inservice and that each mill mode (automatic/manual) toggling is bump less. The loop will be forced to manual if no mill is available to the master or if one the other fuel masters (LSHS LDO) is in automatic mode. In order compensate for lignite quality variability and for inaccuracy of the coal feeders speed, the coal flow signal is calibrated by means of the heat release, calculated by using the boiler as a calorimeter Taking into consideration superheated steam flow (pressure and temperature compensated), drum pressure and feedwater (total boiler heat release), the total boiler heat release is estimated. Deducting of the amount due to total oil flow, the heat release by coal fuel is obtained. The time functions are provided in order to take into consideration the delays due to raw coal transportation on belt conveyors, grinding and pulverized coal transportation to the burners. The estimator integrator is stopped when at least one mill is in start-up, i.e. in service but not loading. For boiler trip the total coal demand is forced to zero. 1.3.2 MILL COAL RATE CONTROL Six of the hereinafter control loops are provided, one for each mill. Each individual mill coal rate control consists of the hereinafter control loops that regulated related coal feeders and belt conveyor speed. a) Coal rate control The coal rate control loop is a simple feedback control To improve the mill response, in case of automatic mode a dynamoic action on coal demand to mill is added, as hereinafter described: I + sT1 Y(s) = U(s) I + sT2 Where: U(s) is coal demand to each mill (coal master output, see 1.3.01), in the frequency domain; Y(s) is coal feeders rate demand, in the frequency domain; T1 > T2, in order to have a demand amplification during transient.

The resulting coal demand, biased if desired by the operator, is compared to mill coal feeders rate (i.e. estimated mill coal flow); the error, through a dedicated controller, sets the mill total coal flow demand, that is sent to the coal feeders control. When the mill outlet temperature exceeds the operating value, but below the trip value, the characterized signal of the mill outlet temperature will be deducted to coal demand (i.e. set point), trying to get back the mill outlet temperature within the range. The loop is forced to manual if both the coal feeders control loop and the belt conveyor speed control loop are selected in manual mode. If mill motor current absorption is low, the loop control output (mill coal flow demand) cannot decrease; if mill motor current absorption is high, the coal demand cannot increase. As mill full load can be reached by 2 feeders at full speed, if only one coal feeder is in service: The set point is halved, in order to keep all the feeders at the same load; The mill coal flow demand is limited at 50%, in order to avoid improper action by the operator.

b) Coal feeders control The mill coal flow demand (set point, t/h) is transformed into a single feeder speed demand (0 100%), being multiplied by 2 (number of feeders at full speed required for full mill load) and ratioed by the number of coal feeders in service; consequently the gain of the total loop doesnt depend on the number of feeders running. The resulting signal, via a high selecting logic, it is compared to minimum coal feeder speed, to avoid that the coal amount transported to the mill could drops below the minimum, causing problem for flame stability. If both mill control and secondary air control are in automatic mode, the proper substoichiometric ratio between coal and air is assured by the loop described in 1.3.06. If mill control or secondary air control is in manual mode, the coal feeders speed demand is limited by the available secondary plus primary air flow. Then the output signal of the above logic, via low selecting logic, is compared to belt conveyors speed (taking into account the number of feeders in service), thus the coal feeder speed cannot increase before the belt conveyors do, avoiding abnormal coal accumulating on belt conveyors itself.

The resulting speed demand is sent to the 3 coal feeders. Each speed demand is forced to zero if the related feeder is not in service and forced to a proper prefixed value during feeder start-up (see ref. [2]). c) Belt conveyors control The characterized mill coal flow demand, via a high selecting logic, is compared to minimum belt conveyors speed. Then the output signal of the above logic, via high selecting logic, is compared to the mill coal feeders rate, thus the belt conveyor speed cannot drop below coal feeders speed, avoiding abnormal coal accumulating on belt conveyors itself. The belt conveyor speed is forced at minimum during automatic start-up (see ref. [2]). For mills HFC01, HFC02 and HFC06 only one belt conveyor each is provided. For other mills (HFC03, HFC04, HFC05) two belt conveyors each are provided, so additional interlocks are foreseen, in order to avoid the first belt speed increasing above the second conveyor speed and so avoiding the risk of improper coal accumulation.

1.3.3

MILL RECIRCULATION CONTROL Six of the hereinafter control loops are provided, one for each mill. Each individual mill recirculation control acts on the related mill recirculation and multiblade outlet control damper. The control loops are simple feedback control loop based on mill coal feeders rate trimmed by the mill outlet temperature. The operator has a biasing facility to shift up down the position demand, established on boiler test, of the final control devices. The mill outlet multiblade damper position will range from 50 to 0 because, if the blades angle exceeds the value of 50, pulverized coal can accumulate upstream the damper. Therefore the closed position (required by B.M.S. during start-up and shut-down sequence, see ref. [2] corresponds to an angle of 50 and the open position corresponds to 0. For maintenance purpose only, the blades can be manually put in the 90 positions, so the transmitter (and loop) range covers the whole span: 90 = 0% 50 = ~44%

 1.3.4

0 = 100%

MILL SWIRLER CONTROL The control loop is simple feedback control loop based on boiler load (SH steam flow) trimmed by the mill outlet temperature. The operator has a biasing facility to shift up or down the position demand, established on boiler test, of the above final control device. The swirler position is forced to a fixed value during mill automatic sequence (see ref. [2]).

1.3.5

MILL OUTLET TEMPERATURE CONTROL Six of the hereinafter control loops are provided, one for each mill. As the coal/gases/air mixture temperature is controlled by mixing hot primary air and coal recirculation gases to hot gases sucked from furnace at mill inlet, this control loop acts on the hot primary air and cold recirculation gases control dampers. The control loop is simple feedback control loop based on mill coal feeders rate, the operator has biasing facility in order to shift up or down the curve established on boiler test. Propepr action are performed according to the request from Burner Management System (ref. [2]) that force the control dampers at proper position, as follows: a) Hot primary air damper: Partially open (approx. X% -- to be defined) to perform mill start-up Fully closed for mill trip or to perform mill shut-down b) Cold recirculation gassed damper: Partially open (approx. X%-- tobe defined) to perform mill start-up Fully closed for mill trip or to perform mill shut-down The oxygen content at mill outlet could be helpful to reduce mill improper operation, therefore an action is foreseen on primary air control damper only to maintain the oxygen content within the range. A low selecting logic compares the P.A. dampers position demand, coming from the mill outlet temperature control, to the outlet signal of oxygen controller, the lowest of them become the actual P.A. damper position demand; it means that P.A. air flow, used to control the mill outlet temperature, will be limited by oxygen content evaluated as hereinafter described, to reduce hazardous oxygen content in air/coal mixture.

Due to the ineffectiveness of an oxygen sensor instlled into the pulverized coal ducts, the oxygen percentage content at mill outlet ius obtained by ratioing the the total oxygen content into drying medium (b) and the total drying medium (air, hot and cold flue gases) flow (a) to mill inlet. a) total drying medium flow across the mill is computed summing (a.1), (a.2) and (a.3): (a.1) total flow across the mill is computed summing (a.1.1), (a.1.2), (a.1.3), and (a.1.4): (a.1.1) evaluated primary air flow to the mill is estimated cia total boiler primary air flow, taking, taking into account the characterized positions of the 6 dampers, as follows. f (Y pa k) Fpa,k = (F1pa + F2pa).
6

f (Y
I=1

pa I

Where : Fpa,k is estimated primary air flow to mill k; F1pa + F2pa is total primary air flow; F(Ypa,k) is characterized position of the primary air control dampepr to mill k.

(a.1.2) evaluated air leakage through the coal feeders is estimated as 3.4 t/h per feeder in service. (a.1.3) evaluated mill leakage is estimated as 10t/h, if the mill motor is running (a.1.4) cold flue gases flow to the mill resuction duct is estimated via total boiler cold flue gases to resuction ducts, taking into account the characterized positions of the 6 control dampers, as follows: f (Y cg k) F cg k = F cg
6

f (Y
I=1

cg I

Where : F cg k is estimated cold gases flow to mill k; F cg is total cold gases to resuction ducts flow;

f(Y cg k) is characterized position of the cold gases control damper to mill k. Total cold flue gases toi resuction resuction ducts flow Fcg is computed subtracting (a.3.2) to (a.3.1): (a.3.1) total boiler cold flue gases recirculation flow is measured at flue gases recirculation fans suction, so it is the sum of the flows to CGR nozzles and to resuction ducts. (a.3.2) total boiler cold flue gases flow to CGR nozzles is computed summing the measured flow to each CGR nozzle. (b) total oxygen flow across the mill is computed summing (b.1), (b.2) and (b.3): (b.1) (b.2) oxygen contained in air flow is computed multiplying air flow (a.1) for the fresh air oxygen content (21%). oxygen contained in hot flue gases flow is computed multiplying hot flue gases flow (a.2) for the oxygen content measured at economizer outlet oxygen contained in cold flue gases flow is computed multiplying cold flue gases flow (a.3) for the oxygen content measured downstream R.A.H.

(b.3)

1.3.6

SECONDARY AIR FLOW CONTROL Six of the hereinafter control loops are provided, one for each mill. The secondary air flow control is designed to maintain the air flow in its proper relationship with fuel for good combustion conditions by operating the associated control dampers, two for each mills. According to the mill status, a high selection logic compares the secondary air demand signal to a fixed value (i.e. minimum secondary air flow . cooling air), the highest of them becomes these point of the mill secondary air flow controller. The S.A. flow set point is compared to the related mill S.A. plus evaluated P.A. flow (temperature compensated) and through a controller sets the demand for the control dampers. According to the mill status, the secondary air demand signal will be as follows: No mill in service: The above signal will be equal to zero, it means only minimum secondary air will be required; Related mill in service; The above signal will be equal to approx. 75% (to be defined) of the averqge S.A. flow to mills in service.

The S.A. flow demand is actually the average demand for each of the two dampers; the operator can settle a bias in order to balance the incidental mismatch between the two dampers. If one damper is on manual, the damper on automatic compensates for the damper not participating in the control. Thus, the bias is continuously calculated when one or more dampers are on manual. When the last is put in auto, the bias is released to the operator at the bias, that is actually between the dampers. The resulting demand to the individual damper is compared to the damper position (measured by position transmitter) and through a high reset [proportional plus integral controller, sets the control output to the I/P converter. Proper firing action are performed according to the request from Burner Management System (see ref. [2]) AND Air & Flue Gases functional group[ (see ref. [5]) that force S.A. control dampers at proper position, that are: 1.3.7 Partially open (approx. X% --to be defined) to perform mill start-up Partially opepn (approx. 30%) to guarantee minimum combustion air flow rate to perform furnace purge sequence Last position for five minutes if the combustion air flow is below the purge rate at the time of the trip, waiting time for purge Fully open for natural draft requirement.

SECONDARY PLUS TERTIARY AIR FLOW CONTROL Six of the hereinafter control loops are provided, one for each mill. The secondary plus tertiary air flow control is designed to maintain the air flow in its proper relationship with fuel for good combustion conditions by operating the associated control damper. According to the mill status, a high selection compares the air demand signal to a fixed value (i.e. minimum mill air flow, cooling air), the highest of them, mulktiplied bythe air master control station output (i.e. excess air demand, see 1.2.02), becomes the set point of the mill secondary plus tertiary air flow controller. The S.A. plus T.SA. flow set point is compared to the related mill S.A. plus T.A. flow (temperature compensated) and through a controller sets the demand for the control damper. According to the mill status, the secondary plus tertiary air deman signal will be as follows:

No mill in service: The above signal will be equal to zero, it means only minimum air will be required; Related mill in service; The above signal will be the characterized boiler load signal (i.e. SH steam flow) Related mill out of service and at least one mill inservice: The above signal will be equal to approx. 75% (to be defined) of the average S.A. plus T.A. flow to mills in service.

The resulting demand to the individual damper is compared to the damper position (measured by position transmitter) and, through a high reset proportional plus integral controller, sets the control output to the I/P converter. Proper firing action are performed according to the request from Burner Management System (see ref. [2]) and Air & Flue Gases functional gluon (see ref. [5]) that force S.A. plus T.SA. control damper at proper position, that are: Partially open (approx. X% -- to be defined) to perform mill start-up Partially open (approx. 30%) to guarantee minimum combustion air flow rate to perform furnace purge sequence Last position for five minutes if the combustion air flow is below the purge rate at the time of thje reip, waiting time for purge Fully open for natural draft requirement. 1.3.8 FLUE GASED TO CGR NOZZKLES FLOW CONTROL Six of the hereinafter control loops are provided, one for each mill. The flue gases to CGR nozzles flow control is designed to maintain recirculation flue gases flow in its proper relationship with boiler load conditions by operating the associated control damper. The recirculation flue gases to CGR nozzles flow set point, based on boiler load (i.e. SH steam flow) and corrected by characterized coal specific heat, is compared to the related recirculation flue gases flow (temperature compensated) and through the controller sets the demand for the associated control damper; the control is based on simple feedback closed loop. The operator has a biasing capability to shift the recirculation flue gases flow set point curve up or down of the established curve based on boiler test.
1.3.9 MILLL COAL BURNERS SEALING COLD FLUE GASES PRESSURE CONTROL

The sealing cold flue gases to coal burners pressure control is designed to maintain the sealing pressure at coal burners within the operating range to avoid expansion joint slagging.

The sealing cold flue gassed to coal burners pressure set point, based on boiler load (i.e. SH steam flow) is compared to pressure value and through the controller sets the demand for the related control damper; the control is based on simple feedback closed loop. The operator has a biasing capability to shift the sealing cold flue gases to coal burners pressure set point curve up or down of the established curve based on boiler test. Six of the above control loop are provided, one for each mill.
1.3.10 MILL RESUCTION DUCT SEALING COLD FLUE GASES PRESSURE CONTROL

The sealing cold flue gases to resuction duct pressure control is designed to maintain the sealing pressure at resuction duct within the operating range to avoid expansion joint slagging. The sealing cold flue gases to resuction duct pressure set point, based on boiler load (i.e. SH steam flow) is compared to pressure value and through the controller sets the demand for the related control damper; the control is based on simple feedback closed loop. The operator has a biasing capability to shift the sealing cold flue gases to resuction duct pressure set point curve or down of the established curve based on boiler test. Six of the above control loops are provided, one for each mill. 2.0 2.1.00 2.1.01 BINARY CONTROL COLD FLUE GASES COLD FLUE GASES TO CGR NOZZLES POSITIONING DAMPER The damper is a flap gate; its position shall be according to measured flue gases flow, as shown by the following table:
Flue gases flow

Fg L < Fg < H Fg > H

Flap gate position

Narrow duct

Large duct

Nozzle section

0% (closed) 10 (open) 70%

Open Closed open

Closed Open Open

Minimum Intermediate maximum

a. Open

The operator opens the valve by issuing the command from the keyboard, it also automatically opens in order to achieve the prefixed position according to cold permissive is required. b. Close The operator closed the valve by issuing the command from the keyboard, it also automatically closes in order to achieve the prefixed position according to cold flue gases flow. No permissive is required. The valve is of inching type, hence during opening or closing travel the valve can also be stooped at any intermediate position by issuing the related command from keyboard; the valve automatically stops as soon as it reaches the prefixed position. If necessary, the operator can adjust the prefixed valve position in order to vary the cold flue gases speed to CGR nozzles by issuing the correct opening/closing command via keyboard. 2.1.02 COOLING AIR VALVE TO CGR NOZZLES a. Open The operator opens the valve by issuing the command from the keyboard, it also automatically opens when cold flue gases flow to related CGR nozzle drops below 3% of normal operating flow. No permissive is required. b. Close The operator closes the valve by issuing the command from the keyboard, it also automatically closes when cold flue gases flow to related CGR nozzle is greater that 3% of normal operating flow for 2 minutes. No permissive is required.