Coordinated Master Control

A BRIEF IDEA ABOUT AUTOMATIC

PROCESS CONTROL
CONTROLLING WHAT?
DIFFERENT MODES OF CONTROL:
Turbine Follow Mode
Boiler Follow Mode
Coordinated Master Control (CMC)

AUTOMATIC PROCESS CONTROL
SYSTEM
PROCESS
CONTROLLED
VARIABLE
LOAD
VARIABLE
MANIPULATED
VARIABLE
PROCESS
INPUT OUTPUT
ANY SYSTEM WHICH HAVE AN INPUT AND A DIFFERENT OUTPUT
DUE TO ADDITION OR DELITION OF ENERGY AND OR MASS CAN BE
CALLED A PROCESS.
EVERY PROCESS ESSENTIALLY HAS THREE VARIABLES NAMELY:
CONTROLLED VARIABLE, LOAD VARIABLE & MANIPULATED
VARIABLE

AUTOMATIC PROCESS CONTROL
SYSTEM Contd..
IN A PROCESS THE CONTROLLED VARIABLE TENDS TO
CHANGE DUE TO CHANGE IN THE LOAD VARIABLE

MANIPULATED VARIABLE COUNTERBALANCES THE
LOAD VARIABLE TO KEEP THE CONTROLLED VARIABLE
WITHIN THE LIMIT OF THE DESIRED VALUE

THE JOB OF AUTOMATIC PROCESS CONTROL IS
TO DETERMINE AND CONTINUALLY UPGRADE THE
MANIPULATED VARIABLE AS LOAD VARIABLE
CHANGES.

AUTOMATIC PROCESS CONTROL
SYSTEM Contd..
SELECTION OF CONTROL SYSTEM IS VERY MUCH
IMPORTANT FOR PROPER CONTROL OF CERTAIN PROCESS.

THERE IS AN INHERENT TIME LAG ASSOCIATED WITH ALL
THE COMPONENTS OF A CONTROL SYSTEM. THE REAL
CHALLENGE OF THE CONTROL SYSTEM IS TO SELECT AND
DESIGN THE CONTROL SYSTEM IN SUCH A FASHION SO
THAT IT CAN COUNTER THE LAGS.

THERE ARE MAINLY THREE TYPES OF CONTROLS THAT
CAN BE ASSOCIATED WITH A PROCESS; NAMELY
PROPORTIONAL (P) CONTROL, PROPORTIONAL & INTEGRAL
(PI) CONTROL AND PROPORTIONAL INTEGRAL &
DERIVATIVE(PID) CONTROL
Controlling what?
1. A steady generation in Unit
2. The Steam pressure at Turbine inlet
3. The combustion in Boiler to achieve
maximum efficiency
4. Different Turbine parameters to keep the
Turbine healthy
Turbine Follow Mode

In this mode:
Turbine follows the Boiler
The Final Steam pressure is controlled by the
Turbine admission valves
The Load is controlled by the Boiler. Boiler
master is kept in Man mode
EHG is kept in Auto. Will act in Pressure
control mode


Boiler

Fuel & Air
PR. Tx.



GRID
EHG
PI Controller
Turbine
Generator
MS Pressure
Actual
Pr. Set Point
Turbine Follow Mode Continued..
Characteristics of Turbine Follow Mode
The Steam pressure at Turbine inlet remains
almost constant
The load may fluctuate depending upon the
combustion in Boiler
In case of large load fluctuation, the
Turbine stress parameters are overlooked
Response to changes in load demand is
sluggish
Boiler Follow mode
In This Mode:
Boiler Follows The Turbine
The Steam Pressure is controlled by
controlling the fuel firing in the Boiler.
Boiler Master is on Auto Mode.
EHG is on Man Mode and EHG acts as
Power Controller

Boiler Follow Mode Contd.
EHG in Power Control means it will try to
maintain the Generator output to a fixed
follow as per the power controller set point
given from EHG console.
Main Steam pressure set point is given from
CMC console and Boiler master set point is
given initially during putting Boiler master
in Auto.
Boiler Follow Mode Contd.
MS FLOW
PD
MS PRESSURE
PID
+ +
Boiler Demand
BOILER
Fuel Contl Air Contl
G
Turbine
LOAD
Load Set Point
MS Pr. Set point
EHG PI Cntrlr
Grid
Characteristics of Boiler Follow Mode
Combustion system is fully Automatic
The Main steam pressure varies as Boiler
response is slow (energy conversion)
EHG, acting in Power Control mode, keeps
the Power output fixed to the set value

Solution.. Solution..
In turbine follow mode, the system goes
through a fast process, overlooks load, load
fluctuation, Turbine parameters
In Boiler follow mode, the system goes
through a slow process, pressure fluctuation
happens in large amount
CMC is answer to the above two challenges
What is CMC?
CMC is a Coordination control between fast
response Turbine and slow response Boiler
It has preset values for producing Unit Load
demand keeping in mind all the primary
protection parameters in mind
The primary aim of CMC mode is to make
the Unit steady and reliable with fixed load
output and minimum pressure deviation
CMC Mode
In this mode:
Boiler Master should be in Auto
EHG should be on Auto and EHG in Power
control mode
Unit load set point given from CMC
console
Fixed/sliding pressure set point given from
CMC console
Run Back
CMC looks after different availability of
Load Bearing equipments
It can restrict the upper limit of load
irrespective of the load set point given
Again whenever any load bearing
equipment trips, CMC brings down the Unit
load to a preset value automatically so that
Unit remains stable and safe
- This feature is called Run Back
Run Back Continued
Equipment Tripping Load Limit
One BFP, CW pump, CEP
Tripping (If std. by Does Not
take start)
125 MW
One FD fan / One ID fan
Tripping
125 MW
One PA fan / One Coal Mill
Tripping
168 MW
Generator/ Turbine Tripping 100 MW (Boiler will run
keeping HP-LP Bypass open)
Run Down
During CMC mode operation, all the
important auto control loops remain in
service.
If any of them can not act properly, CMC
logic understands that there is some
problem
It then brings down the control deviation of
the incapable control loop by changing the
load until the deviation minimizes
- This feature is called Run Down

Run Down Continued
The conditions of the Auto loops are:
1. Drum level 3 element control deviation
>9.8% and BFP scoop (maximum scoop
of BFP A, B or C >95%
2. Air flow deviation >9.8% and FD Blade
pitch (maximum of FD A or B >85%)
3. Furnace Pressure deviation >9.8% and ID
fan scoop <15% or ID fan scoop >85%
4. Coal flow deviation >10% and maximum
Feed rate >90%

Run Back & Run Down
Run Back and Run Down are two most
unique features in CMC logic
Here proper importance is given to all the
relevant drives and the main control loops
are given significant weightage so that they
do not face restriction and the equipments
and/or protections do not reach the limit

Upward Block &Downward Block
Up Directional Blocking:
3 element drum level control deviation >
9.8%
BFP scoop (maximum of scoop of BFP
A, B, C > 93 %
Air flow deviation (set value actual
value) > 9.8 %
FD fan A or B blade pitch > 85%
( Maximum of FD A or FD B)
Upward Block &Downward Block
Up Directional Blocking:
Furnace pressure deviation > 9.8%
ID Fan A or B hydro coupling % > 85%
Coal flow deviation > 10%
Mill feeder rate (Maximum of feeder A to F
) > 90%
Load control deviation > 20%

Upward Block &Downward Block
Down Directional Blocking:
3 element drum level control deviation < -
9.8%
BFP scoop < 15 %
Air flow deviation ( set value actual
value) <- 9.8 %
FD fan A or B blade pitch < 15%
Furnace pressure deviation <- 9.8%
Upward Block &Downward Block
Down Directional Blocking:
ID Fan A or B hydro coupling % <15%
Coal flow deviation <-10%
Mill feeder rate < 15%
Load control deviation <-20%

TSC Margin
Turbine Stress Controller ( TSC) calculates
the thermal stress developed in different
portion of turbine viz. HPT shaft, IPT shaft,
HPT casing , IPT casing, MSV and decides
a margin for load increment or decrement
depending upon instantaneous temperatures.
TSC Margin
Tm: - Mean temperature (C)
ti: - Inner surface temperature (C)
dt :- ti - tm
It is obvious that during load increase; mean
temperature will be less than the inner surface
temperature. The opposite will take place in case
of load decrease.
That means dt is positive for load increase and
negative for load decrease. If we plot a curve of dt
vs. tm, then the instantaneous point can be define
on it. The point must be within the allowable limit
define in the curve.
TSC Margin
Upper temp. margin
Lower temp. margin
dt
Present operating
Point (instantaneous)
(tmi , dtu)
(tmi , dtL)
(tmi , dti)
tm
TSC Margin
Say, for tm being same as that for the current
point, the maximum allowable dt for positive side
is dtu and for negative side is dtL
Then upper temperature margin = dtu - dti and
lower temperature margin = dti - dtL .
If these margins go down a minimum value, TSC
will restrict load increment ( for low upper margin
) and load decrement ( for low lower margin)
While machine is on CMC mode, TSC influences
the load change rate looking after turbine thermal
stress.
Calculation of Shaft Temperature
Ti Shaft Surface Temperature
B Cycle time (0.5)
x1= x1 + (Ti x1)(1 e
-0.5/y1
)
x2= x2 + (Ti x2)(1 e
-0.5/y2
)
x3= x3 + (Ti x3)(1 e
-0.5/y3
)
x= k1x1 + k2x2 + k3x3

(where k1+k2+k3 = 1)
x=Tm (Shaft Mid Temperature, 50%)
a1 = 33672.6, a2 = 3.8119, a3 = -0.0447854
p = (a1 + a2x + a3x
2
), q = R
2
/p * (2.4048)
2
y1 = q, y2 = q/5.27, y3 = q/42.17
Generation of CMC Unit Load Demand
From Unit Load Set Point

PB/VPC
Tracking for
Runback /
Rundown Or
no CMC
1
2 ADD MIN
MAX
CMC in
service
Gen MW
Defeat Switch
Freq.
Influence
MAX S.P. MIN S.P.
To next slide
Generation of CMC Unit Load Demand
From Unit Load Set Point
Contd..
From Previous slide
EHG Hold
Load Rate SP
Up/Down Dir
Block
Runback/ Rundown
Limit
MIN
1
2
2
1
Block
Grad
TSC Rate
Min
Runback/Rundown Rate
Ramp
CMC demand
Generation of Boiler Master Set Point
From CMC Demand
1
2
D
Load. Dev
Steam
Pr. Dev.
ADD
PID
ADD
Boiler
Master
For Changing load
For Steady State
D
Generation of Turbine Master (EHG) Set
Point From CMC Demand
2
Dead Time
Delay
3
PID / P
ADD
MAX
MIN
+
-10MW
-
+10MW
2
EHG
Pr. Dev.
3 +ve Limit
-ve Limit
Load Rate Circuit
1
2
1
2
Load Rate
Runback / Rundown
In Action
Runback in action
Rundown Rate
MIN
Load Rate
SP Stn
PB/VPC
TSC Rate
Runback Rate