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FIG 9.11. The control system for a once-through boiler must be as closely knit as the process itself.
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Set point to feedwater flow controller
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match the feedwater to tcmpcrature response with that of firing rate to temperature. Since both manipulated variables encounter the same dead time related to t,he velocit y through the tubes, their responses are similar. Icortunately, the action of the spray controller also helps make up for any differences in response. Because this dead time varies inversely with flow, hence with thermal power, the process exhibits variable dynamic gain. But the feedforward signal Q is a multiplier in both power and temperature loops, providing gain adaptation.
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Steam-driven Turbines
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When the output from a steam plant is to be used to drive a turbine generator, t,he latter s characteristics must be taken into account. In order to generat,e electric power, the turbine needs an equivalent amount of thermal power. Steam is merely a vehicle which transports the power from the burners to the turbine shaft. The actual flow of steam is not significant,, except in that it determines what the temperature and pressure must bc for a given value of power. The turbine acts like a fixed resistance to the flow of steam, with a downstream pressure determined by conditions in the condenser, usually several inches of vacuum. Thus the pressure drop is nearly equal to the inlet pressure. Thermal power is proportional to the square root of the product of differential and static pressures, which in this case is t he inlet pressure pl itself:
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The speed of a turbine generator is set by a governor which positions the throttle valve with proportional action. The throttle valve is
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250 1 A p p l i c a t i o n s
between the superheater and the t,urbine, in the place of the steam valve shown in Fig. 9.10. Its position changes with variation in turbine speed, which is measured as the frequency of the generated voltage, or with a set-point adjustment. The steam-pressure controller,. then, in a sense sets the thrott le-valve position by setting the governor. The fact that t he t,hrottle-valve position can change with frequency does complicate the control problem somewhat,. Should frequency fall, more power is needed to restore it. But opening the throttle valve does not produce more power. So if steam pressure is to be maintained, the firing rate must be made to vary wit,h frequency. To accomplish this, a frequency-deviation signal is usually added to the output of the set station where the desired power output is introduced.
PUMPS AND COMPRESSORS
There are many ways to control the flow and pressure of streams discharging from pumps and compressors, but all are not equally efficient. Throttling a valve in the discharge line of a cent rifugal pump may be convenient, but it may also be wasteful if long periods of low flow are encountered. And it cannot be done at all with a positive-displacement pump, because pressure ratings would be exceeded. The point is, that the type and size of a prime mover dictate the means which are to be used to control it. This is particularly t rue of compressors which are capable of exhibiting unstable characteristics.
Positive-displacement Pumps
There are two principal classes of pumps: positive-displacement and centrifugal. In positive-displacement pumps, a given volume of fluid is mechanically forced from the suction port to the discharge wit h every rotation of the shaft. In reciprocating pumps, this is done in a periodic fashion, such that outflow pulsates; if multiple cylinders are used, they are phased so as to diminish the amplit ude and period of t he pulsations, smoothing the flow. Often an air chamber is at tached to the discharge line to help absorb these pulsat.ions. If either the stroke or the speed of a reciprocating pump is adjustable, it can be used for metering an accurate amount of fluid. The accuracy of these metering pumps requires that they be free from leakage, part icularly backflow from discharge to suction. This means that their valves must be t,ight-sealing, and the fluid free from particles which might interfere with their action. The fluid must also be incompressible; these pumps often vapor-lock when the fluid contains dissolved or entrained gas. When used with clean liquids, metering pumps are valuable for flow control, particularly where high discharge pressures are encoun-
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