Otsc - Control Final-Boiler

Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Welcome
OTSC Boiler &
its control
S.Dharmalingam
OTSC Boiler Controls - Presentation on 27th MAY 09
Presentation overview
 Critical About Supercritical
 OTSC Boiler vs Drum Boiler Control
 Start-up, Warm-Keeping & Water Sep. Systems
 Steam Temperature Control
 Feedwater Control
 Boiler protections
 Summary

Legend:
CV Control valve
DESH Desuperheater
Eco. Economiser
Eva. Evaporator
FR Fuel rate or Firing rate
FW Feed water
RH Reheater or reheated
Sep. Separator
SH Superheater or superheated
SP Set point

Interchangeables:
Wet mode   Recirculation mode
Dry mode   Once thro mode
WW   Evaporator

What is Critical About Supercritical?
There’s nothing “critical” about supercritical.

“Supercritical” - a thermodynamic expression
describing the state of a substance where there is no
clear distinction between the liquid & the gaseous
phase (i.e. they are in a homogenous fluid).
 Water reaches this state at a pressure above 22.1
Mega Pascals (MPa).
OTSC boiler Controls - Presentation on 27th MAY 09


OTSC Boiler vs Drum Boiler Control

Control system for a OTSC boiler - different from a drum boiler.

Why?
The drum & its associated water walls decouple steam circuits from
water circuits and boiler FW pump, whose function is to maintain
water level in drum.
In OTSC boiler, boiler FW pump responds to unit demand.
Drum unit has a relatively large amount of energy storage - can be

used to provide immediate transient response to load changes.
In OTSC design - small fluid mass has relatively small amount of

energy storage.

Increasing operating pressure produces the desired cycle

efficiency gains - however stored energy reduces as
pressure increases.

Unlike a drum-type boiler, OTSC boiler does not have

a large steam drum to store energy.
Due to this, control system must match, exactly &

continuously, FW flow & boiler firing rate (both fuel
& air) to turbine steam needs, to deliver desired load.

OTSC Boiler
No thick-walled drum at the end of the Eva.

Instead only several thin-walled separators with high
allowable temp. transients.
A further advantageous characteristic - small thermal
storage masses - have a positive effect on flexibility.
Short startup times & large temp. transients over wide
output ranges are possible.

Instead of a thick-walled Allowable temp. transients for

drum, OTSC boiler has Sep. of a 250-bar OTSC boiler -
several thin-walled roughly three times as large as
Separators configured for for the drum in a 175-bar drum
parallel flow. boiler.
Areas Unique to OTSC boilers
• Start-up, Warm-Keeping & Water Sep.

Systems
• Steam temperature control(modified)
• Feed water controls(modified)
• BMS logics(modified)

OTSC BOILER SCHEMATICS
Platen Finish HP Turbine

Superheater Superheater
Separator LT Reheater IP/LP Turbine
Finish
Evaporator Reheater
Wate
Economizer FW pump r
Furnace
FD Fans
HSA
APH Air
HPA PA Fans
Coal & Air CPA
Pulverizers Coal

OTSC boiler - Schematic
FWP
Eco. Evaporator Separators Platen SH DESH Finish SH

To
turbine
Storage
Tank
Boiler
circulation
pump

Start-up, Warm-Keeping &

Water Sep. Systems

Once through boilers
Low Load Circulation System Separator
 The excess flow over the once 1. Separates steam & water
thru flow is separated in during circulating mode
separator; and operation.
 Recirculated back to boiler 2. Runs dry during once thru
directly by the dedicated flow mode.
pump. 3. Smaller in size compared to
drum in a drum type boiler.

Salient Features: Steam Separator
 Multiple nos. of separators( 4 nos).
 Storage tanks(2nos.) for collection from separators.
 Level monitoring in Storage tank. It prevents boiling water

from flowing into the superheaters.

START UP SYSTEM
SH
Sep.
EVA.
ECO.
Sep. Storage Tank
LT Water return
valves
Flash tank
MEFCV
Check
valve
HWL-1
To
BWCP condenser
HWL-2
Make up
Mixing Tee water
Spray
water HPH Deaerator
FWCV BFP

Start-up, Warm-Keeping &Water Sep. System - Schematic

Separators &
Storage tanks
Separator
4 nos.
Storage Tank
2 nos.
Sep. OD 558.8 X 63.5 mm
Tank OD 660.4 X 73.0 mm

Boiler water
circulating
pump
Parameter:
Pr. 129 kg/sq. cm(g)
Temp. 244 deg. C BWCP
Flow : 847 t/hr. 1 no.
DP : 4.2 kg/sq. cm
Rating 420 KW
Flash tank

Start-up, Warm-Keeping &

Water Sep. System controls
 Separator Storage Tank Level Control
 Minimum Eco. Flow Control (MEFC)
 Warm-Keeping Level Control
 Flash Tank Drain Tank Drain Water Temp. Control

Separator Storage Tank Level Control

Control objective :
• Maintain Storage tank Level during transients
Separator level demand :

• Derived from level error & Total fuel flow
Control action :
• Controller positions 2 nos. water return valves - HWL1 & HWL2
to maintain separator level.
• HWL1 & HWL2 valves - controlled in a split range manner. HWL1
responds first & then HWL2 when the HWL1 exceeds its linear
operating range.

STORAGE TANK LEVEL SET POINTS
Two (2) Tanks Required

NOTES:
Storage
.
tank level 1. Not to scale
2. Dimensions, M (in.)
set points AXIAL VENT
UPPER WATER LEVEL TAPS

(3) (120 DEG. APART)
13.93 1.0 (39.4)
(548.4) Trip Level
12.94 1.0 (39.4)
(509.4) Alarm Level
11.94
NWL : 7.47 m (470.0)
HWL-2 10.84
100% open HWL-1 100% open
CENTERLINE WATER LEVEL TAPS

(427.0)
HWL 1 CV: 9.75
(384.0)
14.9352 (588.0)
Open HWL-2
- Start open : 8.66 m 8.66
(341.0)
Open HWL-1
- 100 % open : 10.84 m 7.47 Storage Tank Level Control Set Point
(294.0) NWL – ½ way between level taps
HWL 2 CV:
One of the conditions to open
4.0 warm-keeping inlet stop valve
- Start open : 9.75 m Unit in wet mode
(157.5) (control valve remains closed)
- 100 % open : 11.94 m 3.0

(118.1)
Level control to manual,

Close HWL-1 close HWL-2
1.0 (39.4)
0.5 (19.7)
LOWER WATER LEVEL TAPS
(3) (120 DEG. APART)
AXIAL WATER OUTLET

START UP SYSTEM
SH
Sep.
EVA.
ECO.
Sep. Storage Tank
LT Water return
valves
Flash tank
MEFCV
Check
valve
HWL-1
To
BWCP condenser
HWL-2
Make up
Mixing Tee water
Spray
water HPH Deaerator
FWCV BFP

Separator Storage Tank Level Control
• Water level influenced by fluctuations from
– Steam Pressure
– Feed water flow rate
– Steam and water expansion
– Outlet flow rate of recirc. pump &
– Firing rate.

SH
Minimum Eco. Flow Control
Sep. (MEFC)
EVA.
Control objective:
Sep. • To Maintain min. Eco.
ECO.
Storage inlet flow to ensure
Tank
LT
adequate Eva. flow during
start-up operation.
Check
MEFCV
valve
• To Maintain min. boiler
water circulating pump
BWCP (BWCP) DP.
Mixing Tee
• Initiate automatic control
action to support unit
Feed Water
automation.
Minimum Eco. Flow Control (MEFC)

Control action
• BWCP is started following the start of a FW pump.
• BWCP circulates water from Eva. outlet back to Eco. inlet.

• MEFCV located at outlet of BWCP, controls Eco. inlet flow during
start-up phase.
• Demand for this CV - established

based on measured Eco. inlet flow
compared to a min. boiler flow SP.
• Limit action provided to this CV

to ensure that min. BWCP DP is
maintained.

Warm-Keeping system Level Control

Control objective:
• To Maintain Storage tank

downcomer (wet leg) level.
• Initiate automatic control

action to support unit
automation.
wet leg
Warm-Keeping system Level Control
Control action:
When wet-to-dry transfer is complete - the circulation shut-off

valve closed & recirculation flow stopped. Piping between the
storage tanks & this valve, and storage tanks & HWL1/HWL2
valves, is maintained in warm condition by FW flow from Eco.
outlet through a warm-keeping system.
With warm-keeping system operating, liquid level (DP) in tank wet

leg (recirculation downcomer) is controlled by the warm-keeping
level CV.
Valve is controlled in response to measured storage tank

downcomer(wet leg) level compared to a SP.

START UP & WARM UP SYSTEM
SH
Sep.
EVA.
ECO. To SH Sp.
L Water Sys.
T
L Warm Keeping
T level CV
Flash tank
MEFCV
Check HWL-
valve 1
M To condenser
BWCP HWL-2
Make up water
M
Mixing Tee
HPH Warm up supply Deaerator

From ECO. outlet
FWCV BFP

Flash Tank Drain Tank Drain Water

Temp. Control
Control objective:
• To Maintain desired condensate temp.

• Initiate automatic control action to support unit automation.

FLASH TANK DRAIN TANK SYSTEM
Condensate from
Flash tank TE
Min. rec.
LT level CV
Flash tank drain tank
Min. rec.
level CV
Drain water Min. rec. Flow CV

Temp. CV
Condensate pumps To Condenser
Cooling TE
water

Flash Tank Drain Tank Drain Water

Temp. Control
Control action:
An overflow & manual drain from drain tank provided to

discharge condensate into the plant drains’ clean water sump.
To control temp. of condensate leaving drain tank, a “cooling

water” CV is provided.
Valve positioned by a PI controller that responds to the error

between measured drain water temp. as compared to a SP.

Start up system – Transition load

Wet to dry transitions can occur by fluctuations in firing rate &
feedwater flow at the moment of transfer, but also at higher loads.
Superheated steam conditions coincide with a particular temp. &
pressure. An increase in pressure without a corresponding
increase in temp. can result in loss of superheated conditions (wet
operation).
To ensure the transition occurs in one direction only, steam temp.

controlled via the manipulation of FR / FW ratio (FR/FW). In once-
through operation, the ratio of firing rate to feedwater flow that
controls the Sep. outlet temp.
Higher FR/FW ratio causes furnace wall exit quality to increase

above 100%. Simultaneously, DESH spray-water flow will increase
to maintain main steam temp. which will contribute to increasing
the furnace wall quality.

SH System

SH SYSTEM
Sp. water
Header
Header
Outlet
Outlet
HEADER
From Sep.
HEADER
INLET
INLET
Platen DESH FSH HPT
Header
Header
Outlet
Outlet
Sp. water

Importance of Consistently
Accurate Steam Temp.
• Of various control loops for a fossil boiler, SH steam temp. plays a
most critical role in unit performance.
• Steam temp. - directly related to overall unit efficiency - deviations

from SP even by few degrees represent a considerable decrease in
efficiency.
Cycling of steam temp. caused by poor control functionality - highly

undesirable increase in thermal stress on SH. Over time, stresses
cause ruptures in SH tubing - results in boiler trips & forced
outages for repair. Repairs take several days & loss due to
generation can be millions of rupees.
Thus, achieving consistent, responsive Steam temp.

maximizes efficiency & assure uninterrupted operation.

Dependence of Steam temperature

• Raise in steam temperature …. obtained by
Firing rate (OR)

Feed water flow (OR)
BOTH
Called as steam temp. control by ratio adjustment
OTSC boiler designs require a min. FW flow to protect

furnace tubes from overheating. Hence FR is to be
adjusted to control steam temp. until load exceeds the
min. FW flow.

Dependence of Steam temperature
Since all feedwater entering the Eva. becomes steam

(once-through mode), throttle pressure is directly
related to FW flow.
At constant FWP discharge pr.
• Increase in FW flow - Steam pressure decreases.
• Reduction in FW flow - Steam pressure increases.
Since all FW entering the boiler must be heated into SH

steam, the FR rate controls (fuel & air) are modulated to
provide the required heating.
The ratio of FW to FR determines the final value for main

steam temp.

SH Steam Temp. Control
In OTSC boilers, steam temp. has no natural, uncontrolled

characteristic curve - always established by the control system
(automatic or manual).
In steady state condition, ratio of FR to feedwater flow determines

the final steam temp. But unfortunately, steam temp. response to
changes in FR/feedwater flow ratio is somewhat sluggish during
load changes.
A control system which depends solely on adjustments of FR to

feedwater flow cannot fully prevent relatively wide deviations in
temp. during load changes or other disturbances.

SH Steam Temp. Control (General)
Overall SH steam temp. accomplished with adjustment of spray

water control & manipulation of FW flow.
Two spray water CVs act to maintain final SH outlet steam temp. &
FW flow adjusted in response to SH DESH average differential
temp.
In short term, final SH Temp. fluctuations minimized by the fast

acting spray water CVs.
In long term, control action automatically re-adjust steam temp. at

each control points(Eva., platen SH) in response to changes in
corresponding heat transfer rates.

SH Steam Temp. Control (General)
This approach provides a high level of disturbance rejection.
Ensures SH spray water CVs remain in control range by ultimately

adjusting Eva. outlet steam conditions/heat transfer.

Control objective:
• To maintain final SH steam temp.
• Initiate automatic control action to support unit automation.
• Provide saturation protection.
• Calculate average SH spray station differential temp. (for use in

FW demand development).

Control action:
Control structure - a cascade arrangement - master controller acts on

the error between SH outlet (average) temp. & a load dependant SH
outlet temp. SP.
Output of this controller represents reqd. temp. entering final SH

section to achieve the desired temp. at final SH outlet.
An “over/under firing” feed forward is added to master controller’s

output for improved response. This signal developed by comparing
the rate of change in steam flow to rate of change in fuel flow.
Over firing (rate of change in fuel flow in excess of rate of change in

steam flow) decreases the master’s output.

SH Steam Temp. – Control Scheme

SH Outlet
Temp. SH DESH
Outlet Temp.
SHO SP 
P I
Rate of
MS Flow + 
Rate of - P ID
Fuel Flow
SH Spray
CV
Demand


This signal is an anticipatory action to offset the tendency for
increased steam temp. resulting from a temporary imbalance
between cooling (steam flow) and available heat (firing rate) when
over firing.
The signal has opposite effect when under firing (increases master
controller output) since in this case the temporary cooling/heat
imbalance tends to decrease steam temp.
Resulting modified master output provides the SP to a slave
controller. This controller acts on this SP as compared to steam temp.
measured at DESH outlet.
The slave controller output, subject to an overriding “saturation”

protection, provides the position demand to each of the spray water
CVs.


Saturation protection
Saturation protection - active at reduced unit load when the SH

pressure is subcritical & prevents over spraying by limiting the
spray valve demand.
Saturated steam temp. is established from measured Sep. outlet

pressure, adding 11 deg. C establishes the min. permissible
degree of superheat.
Increased spray is prevented by limiting the final spray valve

demand in the event measured DESH outlet temp. drops below
the established min. level of superheat.
Average SH spray station differential temp. is calculated for use in

feedwater demand development.

RH System

RH SYSTEM
Sp. water
Header
Header
Outlet
Outlet
HEADER
HEADER
INLET
INLET
HPT LT RH FINISH IPT
RH
Header
Header
Outlet
Outlet
Sp. water

Reheat Steam Temp. Control (General)
RH outlet steam temp. - controlled by a combination

of two spray water CVs & fuel nozzle tilt positioning.
RH spray water CVs - positioned by a cascade control.
Demand for fuel nozzle tilts - developed by a PID

controller.

Reheat Steam Temp. Control
Control objective:
• To maintain reheat steam temp.

• Initiate automatic control action to support
unit automation.
• Provide saturation protection.


Control action:
Control concept - similar to SH spray water control.
Master controller for each CV acts on the corresponding

RH outlet steam temp. as compared to a load dependent
SP.
Slave controller positions the reheat spray CV in

response to master output (with over/under firing
feedforward) as compared to the associated RH DESH
outlet temp.

RH Steam Temp. Control – Control Scheme

RH Outlet RH Outlet
Temp. RH DESH Temp.
Outlet Temp.
RHO SP  RHO SP 
P I P ID
RH Tilt
Rate of Demand
MS Flow + 
Rate of - P ID
Fuel Flow
RH Spray
CV
Demand

Nozzle tilt:
• Prevent an increase in nozzle tilt upward position in

the event any spray CV is full open.
• Close RH spray CV through nozzle tilt positioning.
• Initiate automatic control action to support unit

automation.

Nozzle Tilt in a Tangential
Corner Fired boiler

Nozzle tilt:
Totally three sets(twelve nozzle) of tilt drives - one set for each
main WB, and one for separated overfire air (SOFA) WB. Each
drive positioned individually.
A controller develops demand to all tilt drives; The controller acts

on the RH outlet (average) steam temp. as compared to SP.
The SP from reheat spray control provides the base SP for tilt
control. This base SP is reduced by a max. of 5°C for the purpose
of forcing the RH spray water CVs valves closed in the long term.


Nozzle tilt:
In the event of a positive temp.error (temp. above SP)

control action simultaneously decreases nozzle tilt
position & increases spray water.
Due to relatively fast response of spray water control,

temp. error will be quickly eliminated by spraying, with
zero error, the tilt will stop moving.
The overall response provides fast temp. control while

avoiding continued unit operation with RH spray water &
associated reduction in unit heat rate.

Feedwater Control
• Drum & OTSC boilers - the most obvious

difference - the absence of a water level in
an OTSC boiler.

Feedwater Control
Control objective:
• Develop total unit FW demand to support unit load.
• Adjust FW demand to maintain desired Sep. outlet Temp.
• Adjust Sep. outlet Temp. SP as required to maintain

acceptable SH spray control range.
• Maintain min. required Eco. inlet flow.

Feedwater Control – Control Scheme

Sep. outlet
SH DESH
Temp.
T
Boiler
Master Min. Eco.
Demand
 inlet Flow
SP (40%)
P I

P I
< Sep. Level
demand
Feed Flow

> P I
Feed water Demand

Feedwater Control
Control action:
SP for FW established predominately by Boiler Master demand.
This minimizes temp. fluctuations that may result from varying

dynamic response between the firing & feedwater control
systems (as they relate to boiler fluid heat transfer) thereby
lessening the dependence on feedback correction.
SP for FW established by a cascade controller arrangement.

Feedwater Control
Master controller acts on Boiler Master demand and average SH
DESH differential temp. Its output represents the required
adjustment to Eva. heat transfer.
Slave controller acts on Sep. outlet Temp.
This controller acts to adjust FW in response to firing system

disturbances and the relatively fast effect they have on separator
outlet steam temperatures.

Feedwater Control
The corrected FW SP is not allowed to decrease below the min.
Eco. inlet flow SP (wet mode) when BWCP is not in service & unit
in operation.
This ensures min. Eco. inlet cooling flow maintained by FW supply

system in the event start-up system is not available.
The FW SP is subject to a second “wet mode” FW demand

developed to support Sep. storage tank level control. The
resulting demand provides the SP to a FW main controller. The
feedback to this controller is the lower of total FW flow or Eco.
inlet flow.
With the start-up system in service (wet mode), Eco. inlet flow is
greater than FW due to recirculation & therefore feedwater flow is
the selected feedback.

Boiler protections

Burner Management System
Addl. logics introduced compared to drum boilers (for MFT

conditions)
Eva. tube metal temp. very high
Eco. inlet flow less than minimum.
Separator level very high
SH pressure very high
Loss of DCS control capability

Evaporator MTM Measurement
Separators
Furnace Furnace Furnace

Furnace
Upper Front Upper Rear Upper side
Upper side
header header header
header
MTM
TC
Furnace Furnace Furnace

Furnace
intermediate intermediate intermediate
intermediate
header header header
header
MTM
TC
Furnace Bottom Ring header
ECO.

Eva. Tube Metal Temp. Measurement

• Heated water goes to 4 nos. intermediate headers & then to
corresponding 4 nos. Upper headers.
•Each upper header has four riser

pipe outlets carrying mixture of
steam & water and forms one inlet
to Separators a,b,c&d.
•Totally 16 inlets going from this

system for 4 nos. Separators.

Heat transfer crisis
Boiling process can be considered also in

heat transfer terms. Heat flux in furnace by
the combustion process is extremely high.
Critical value that heat flux can reach which

results in a sudden decrease of heat
transfer capacity of tube - called as
departure from nucleate boiling (DNB),
dryout, burn out, critical heat flux.
Phenomenon responsible for this problem -

transition from annular boiling state to
misty/drop state. In this state, tube wall is no Dryout occurring in
longer covered with water. an Eva. Tube.
This dryout causes drastic fall in waterside

heat transfer coefficient.

Boiling within Eva. Tubes
Boiling process in a Eva. tube

begins with single-phase water flow
in the lowest part of the Eva.
Heat transfer from furnace

produces initially some steam
bubbles.
Continuous heat transfer increases

steam content in the mixture.
In annular boiling state of the Different types of water/steam

steam/water mixture, tube wall is flow during the boiling process
still covered by a water film, but as
steam content increases water can
be found in the tube as mist only.
This state called as misty/drop
state.
Eva. Tube metal temp.

In drum boilers, large dia. tubes used to minimize flow
resistance - sufficient amount of steam & water can
flow through evaporator tubing by natural circulation.
By designing for a
sufficiently high
circulation rate, water
passing through the
tubing never
completely evaporates
to steam & a liquid film
maintained on the tube
wall so that DNB and/or
dry out do not occur.

Evaporator Tube metal temp.

In OTSC boiler - no distinction between liquid & vapor
phases & there is continual increase in fluid temp. With
unbalances in heat absorption & variations in flow rate due to
hydraulic resistance differences from tube-to-tube, variations
in tube temp. occur.
If unbalance in temp. not

limited, high thermal
stresses will result – leading
to tube failure.

Evaporator Tube Metal Temp. Measurement

• Eva. outlet tube metal temp. monitored for indication of
excessive overheating.
• Overheating - indication of over-firing, low waterwall flow,

or a combination of both.
• If tube metal temp. exceed the SP, an automatic trip of fuel

initiated thro’ BMS.
• This protects the tubes from overheating & potential failure.

Eva. Tube Metal Temp. Measurement
76 nos. TCs for measuring Metal Temp. at the inlet of

intermediate headers.
• 76 nos. TCs for measuring Metal Temp. at the inlet of upper

outlet headers.

Burner Management System
Evaporator tube metal temp. very high (X/152)

Eco. inlet flow less than minimum

• Eco. inlet water flow low condition introduced - as
low flow through economizer & subsequently thro’
Eva., SH/RH will damage the tubes.
•Eco. flow signal taken to BMS for tripping the boiler
if flow is < the desired min.

Separator water level very high
 Excessive water level in Sep. can cause water to

reach SHs & subsequently to turbine.
 As there is no mechanism to monitor water level
after Separator in supercritical conditions - boiler
tripped on very high water level in Sep.

SH pressure very high
For safeguarding against excessive SH steam

pressure:
 Used in Yung-Hung project where safety valves
are used for 30% relieving capacity.
 Not used for Barh (safety valves for 100%
relieving capacity used).

Loss of DCS control capability
Some of the rapidly varying signals used for MFT

- such as Eco. inlet flow very low, separator
water level very high etc., derived from DCS.
Also these are controlled from DCS.
Hence, loss of control capability of DCS can
affect boiler safety.
Hence, boiler tripped in the event of loss of DCS.

Summary
Drum Boiler OTSC Boiler
Steam generation takes place only in Fluid flows directly through all
furnace Water Walls sections of boiler (Eco., Eva.& SH)
Fixed point of evaporation Boiler feedpump is driving force

Steam/water separation takes place in drum Steam temp. controlled by
adjustment to FR to FW ratio
Drum operates at sat. point, which changes Requires elaborate startup
with Load system
Large diameter tubes for steam/water Sensitive to impurities in water

mixture promotes circulation
Steam temp. controlled by spray-water Fast response to sustained and
injection & heat distribution transient load changes
Quick response to transient load changes Lower start up time.
Slower response to sustained load changes

CONCLUSION
OTSC boiler with a properly designed control system should

be considered as a flexible partner in the power system,
suitable not only
• for base load operation,

• but also capable of rapid load cycling duty.

References:
1. The Development of an Advanced Control System for
Supercritical Pressure units – IEEE paper
2. The Flexibility of the Supercritical Boiler as a partner in
Power System Design and Operation – IEEE paper.
3. DEB Co-ordinated control Steam Temperature for Once-
through Super-Critical Boilers – Metso automation.
4. DEB Co-ordinated control for Once-through Super-Critical
Boilers – Metso automation.
5. Fossil Fuel Power Plant - Steam Temperature Controls - ISA-
ds77.44.01-2006.
6. Alstom design documents.

Have a nice day!
It is a privilege to be
Associated with YOU.
Have a nice learning

Otsc - Control Final-Boiler

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Bharat Heavy Electricals Limited TIRUCHIRAPALLI

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler Controls - Presentation on 27th MAY 09

What is Critical About Supercritical?

There’s nothing “critical” about supercritical.

OTSC boiler Controls - Presentation on 27th MAY 09

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler vs Drum Boiler Control

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler vs Drum Boiler Control

Control system for a OTSC boiler - different from a drum boiler.

In OTSC boiler, boiler FW pump responds to unit demand.

Drum unit has a relatively large amount of energy storage - can be

In OTSC design - small fluid mass has relatively small amount of

OTSC Boiler Controls - Presentation on 27th MAY 09

Increasing operating pressure produces the desired cycle

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler vs Drum Boiler Control

Unlike a drum-type boiler, OTSC boiler does not have

Due to this, control system must match, exactly &

OTSC Boiler Controls - Presentation on 27th MAY 09

No thick-walled drum at the end of the Eva.

OTSC Boiler Controls - Presentation on 27th MAY 09

Instead of a thick-walled Allowable temp. transients for

Areas Unique to OTSC boilers

• Start-up, Warm-Keeping & Water Sep.

• Steam temperature control(modified)

• Feed water controls(modified)

OTSC Boiler Controls - Presentation on 27th MAY 09

Platen Finish HP Turbine

Separator LT Reheater IP/LP Turbine

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC boiler - Schematic

Eco. Evaporator Separators Platen SH DESH Finish SH

OTSC Boiler Controls - Presentation on 27th MAY 09

Start-up, Warm-Keeping &

OTSC Boiler Controls - Presentation on 27th MAY 09

Once through boilers

Low Load Circulation System Separator

OTSC Boiler Controls - Presentation on 27th MAY 09

Salient Features: Steam Separator

 Multiple nos. of separators( 4 nos).

 Storage tanks(2nos.) for collection from separators.

 Level monitoring in Storage tank. It prevents boiling water

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler Controls - Presentation on 27th MAY 09

Sep. OD 558.8 X 63.5 mm

Tank OD 660.4 X 73.0 mm

OTSC Boiler Controls - Presentation on 27th MAY 09

OTSC Boiler Controls - Presentation on 27th MAY 09

Start-up, Warm-Keeping &

 Separator Storage Tank Level Control

 Minimum Eco. Flow Control (MEFC)

 Warm-Keeping Level Control

 Flash Tank Drain Tank Drain Water Temp. Control

OTSC Boiler Controls - Presentation on 27th MAY 09

Separator Storage Tank Level Control

Separator level demand :

OTSC Boiler Controls - Presentation on 27th MAY 09

Two (2) Tanks Required

set points AXIAL VENT