WELCOME TO ON LINE TRAINING

Coordinated Master control (CMC) for drum type units

Unit coordinated control (UCC) for drum type units

Unit coordinated control for once through super critical units

Static calibration of unit controls (Unit Calibrator)

By: Dinesh Chandra

Sumit Kumar Mittal
Unit Control
Control of the Boiler and Turbine
as a unit
Introduction

Unit coordinated control (UCC) for drum type units

 UCC Introduction
 Operator Interface
 UCC operating modes
 UCC load ramper scheme
 Fixed and Sliding pressure control
 Contingencies (runbacks and rundown)

Unit coordinated control for once through super critical units

Static calibration of unit controls (Unit Calibrator)

Introduction
Energy Conversion:

Fuel (Boiler Input) Steam Pressure Megawatt

(Turbine input) (Generator output)
Power Plant Operation
(a) Boiler Operation:

Energy input as fuel ( coal / oil / gas ) through Mills / Coal Feeders

Air input though PA Fans / FD Fans

Combustion of fuel in the furnace

Maintaining proper O2 content in the furnace

Maintaining energy storage in the form of Steam Pressure

Automatic controls taking part in the energy conversion :
 1. Boiler Master Control
 2. Fuel Flow Control through Coal Feeders
 3. Air Flow Control through FD Fans
 4. PA Header Pressure Control through PA Fans
 5. Coal Air Mixture Temp. Control
 6. Furnace Pressure Control through ID Fans

Other important controls
 a. Drum Level Control
 b. SH Outlet Steam Temp. Control
 c. RH Outlet Steam Temp. Control
 d. Furnace Pressure Control
 e. De-aerator Level Control etc.
Boiler Control
Power Plant Operation
(b) Turbine & Generator Operation :

Turbine converting thermal energy of steam pressure into kinetic energy.

Generator converting kinetic energy of turbine into electrical energy as Megawatt.

Control of Steam Input to Turbine through Main Steam Stop & Control Valves having
Hydraulic actuators through –
Electro Hydraulic Controller providing prime control
Mechanical Hydraulic Controller serving as back up to EHC

The EHC consists of the following controllers :

 Speed Controller,
 Load Controller and
 Pressure Controller.
Turbine Control
Introduction
Disturbance to Steady state –
1. Change in Unit Load Demand
2. Change in Coal Quality
3. Change in grid Frequency
4. Tripping of Auxiliaries
5. Islanding/House load operation
6. Operation of load shedding relay

Result: Disturbance to important Boiler parameter –

1. Drum Level
2. Steam Temperatures
3. Furnace Draft
4. PA Header Pressure

Operation Difficulties faced during independent operation of

Boiler & Turbine
- Number of simultaneous actions / operations are required to be taken to have control
over boiler and turbine and to get desired / reliable energy balance .
Boiler & Turbine Coordinator
Introduction
Automatic Boiler & Turbine Coordinator
By close coordination, we mean that boiler should produce the steam as required by
the turbine to generate the desired Mega Watt output.

Action required by Boiler: - Have a control over the steam pressure of boiler
Action required by Turbine:- Have control over generated MW

Task of Automatic Boiler & Turbine Coordinator

Quick and reliable energy balance between boiler & turbine

Enhance the response of the boiler and turbine control systems

Maintain the outputs of the boiler, turbine and other plant auxiliaries within safe
operating limits

Reduce the overshoots in generation, throttle pressure and steam temperatures
during and after load changes

Increase the availability , stability and efficiency of the plant,

Make use of full potential of both Boiler & Turbine in order to provide
rapid load changes.
Coordinated Master
Control (CMC)
A
General philosophy
Operating Mode of CMC
1. MANUAL MODE :

Boiler and Turbine are independently in operation

Boiler fuel flow control & air flow control in manual or auto

Boiler master kept in manual

Turbine may be kept in Initial Pressure mode or in Limit Pressure mode

No Run Back action in this mode
Operating Mode of CMC
2. BOILER FOLLOW MODE :

Boiler and Turbine are independently in operation

Boiler is following the Turbine Load

Boiler Master controls Throttle Steam Pressure in auto

Air & Fuel flow control in auto with cross limiting & calorific value correction

Turbine controlling MW in Limit Pressure Mode fairly constant & very effectively

Switching over to Turbine Follow Mode on Turbine Run Back in Action,

Steam pressure variations are quite significant during various disturbances due to large
delay in energy conversion from fuel to steam pressure .
Operating Mode of CMC
3. TURBINE FOLLOW MODE :

Boiler and Turbine are independently in operation

Throttle Steam Pressure is controlled by turbine in Initial Pressure Mode

Air & Fuel feed in auto with cross limiting & calorific value correction

Boiler controls MW in auto

It takes a long time to control & stabilize the load after a disturbance

Turbine Run Back is effected in this mode
Operating Mode of CMC
4. COORDINATED MODE :

Both Boiler and Turbine are coordinating each other & mutually adjusting each other’s
parameters

Load & Pressure Demand for boiler as well as turbine are simultaneously generated

Load Demand for Turbine is suitably delayed to allow Boiler to build up desired energy
level (Steam Pressure)

TSE upper & lower margins are effective

Max. & Min. load limits are effective

Boiler Master is kept on auto

Air & Fuel feed in auto with cross limiting & calorific value correction

Switching over to Turbine Follow Mode on Run Back in Action,

Both load ( MW ) and steam pressure are maintained fairly constant and quite
effectively

Frequency Correction on Load Demand beyond an allowable dead band
Operating Mode of CMC
In addition to the above , following features are also available in this mode :
RUN BACK ACTION

On tripping of any of the unit auxiliaries, the unit capability of generating full load is
reduced

Turbine Run Back Action will be initiated

Megawatt output is reduced up to the capable limit at a predefined rate (Runback rate)

Coordinated Mode switch to Turbine Follow Mode.

FREQUENCY CORRECTION ON LOAD SET POINT

On change in frequency beyond the preset dead band of +0.5 to -1.0 Hz from the set
value of 50 Hz, a suitable correction on unit load set point within specified limits is
applied at the discretion of the operator.
Logic Description of CMC
LOAD SET POINT GENERATION

The load demand of the unit is either by load dispatch center or by the operator.

This signal is limited by maximum and minimum load limits .

frequency correction can be switched on / off by the operator in coordinated mode.

LOAD SET POINT RAMPING

Ramp rate (MW/MIN) is entered by operator.

TSE margins have been taken into consideration to take care of turbine stresses.

Load set point so generated is limited by max. and min. load limits.

In Manual / Boiler Follow Mode , the ramp generator tracks the Turbine Load Set Point
/ actual MW

The load set point can be changed by the operator only in Coordinated / Turbine
Follow Mode .
Load Set point Integrator
Logic Description of CMC
Logic Description of CMC
UNIT CAPABILITY

Based on the running status of the following plant auxiliaries, unit capability is
calculated :
i) ID FAN
ii) FD FAN
iii) AIR PRE HEATER
iv) BFP
v) CWP
vi) CEP
vii) COAL MILL / COAL FEEDER
viii) PA FAN

Minimum output of the individual capabilities of all the plant auxiliaries forms Unit
Running Capability .
Logic Description of CMC
RUN BACK

On tripping of any of the auxiliary equipments, the capability of the unit is reduced.

Load must be reduced up to the capable limit of the unit with a rate (runback rate)

For each set of drive there is a particular gradient, by which the running auxiliaries and
unit will be unloaded.

This action of load reduction on tripping of any of the auxiliary equipments is called
RUN BACK ACTION

It is effected in Turbine Follow Mode.

Under Manual mode of operation , no run back action has been envisaged .

Under the effect of Run Back Action, Boiler Follow / Coordinated Mode is automatically
transferred to Turbine Follow Mode
 CMC configuration and mode selection
Runups
AUTOMATIC Increase CMC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES MEGAWATTS
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase
MW
Block Decrease
PT FW STEAM FLOW
A Set point

- +

∑ CMC Boiler Turbine

pressure PID PID Follow PID Follow
Controller Controller Controller
F(x)

Y
0 ∑ ∑
T1 A Y N
N
T3 Y
N
T4
MODE OF OPERATION
∑ N
S. NO. MODE
BOILER
TURBINE T1 T2 T3 T4 T5 Y
MASTER T5
LAG
1 MANUAL MAN M LOAD CNTRL N N N N N

Y 2 BOILER FOLLOW BF A LOAD CNTRL N N N N N Boiler

N
T2 T A Master
PRESSURE
3.1 TURBINE FOLLOW TF A N N N Y N
CNTRL

PPESSURE
3.2 RUNBACK + TURBINE FOLLOW A N N N Y Y
CNTRL

To Turbine 4 COORDINATED MASTER CONTROL CMC A LOAD CNTRL Y Y Y N N To Combustion Control

(Load set point)
 CMC – MANUAL MODE
Runups
AUTOMATIC Increase CMC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES MEGAWATTS
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase
MW
Block Decrease
PT FW STEAM FLOW
A Set point

- +

∑ CMC Boiler Turbine

pressure PID PID Follow PID Follow
Controller Controller Controller
F(x)

Y
0 ∑ ∑
T1 A Y N
N
T3 Y
N
T4
MODE OF OPERATION
∑ N
S. NO. MODE
BOILER
TURBINE T1 T2 T3 T4 T5 Y
MASTER T5
LAG
1 MANUAL MAN M LOAD CNTRL N N N N N

Y 2 BOILER FOLLOW BF A LOAD CNTRL N N N N N Boiler

N
T2 T A Master
PRESSURE
3.1 TURBINE FOLLOW TF A N N N Y N
CNTRL

PPESSURE
3.2 RUNBACK + TURBINE FOLLOW A N N N Y Y
CNTRL

To Turbine 4 COORDINATED MASTER CONTROL CMC A LOAD CNTRL Y Y Y N N To Combustion Control

(Load set point)
 CMC – BOILER FOLLOW MODE
Runups
AUTOMATIC Increase CMC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES MEGAWATTS
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase
MW
Block Decrease
PT FW STEAM FLOW
A Set point

- +

∑ CMC Boiler Turbine

pressure PID PID Follow PID Follow
Controller Controller Controller
F(x)

Y
0 ∑ ∑
T1 A Y N
N
T3 Y
N
T4
MODE OF OPERATION
∑ N
S. NO. MODE
BOILER
TURBINE T1 T2 T3 T4 T5 Y
MASTER T5
LAG
1 MANUAL MAN M LOAD CNTRL N N N N N

Y 2 BOILER FOLLOW BF A LOAD CNTRL N N N N N Boiler

N
T2 T A Master
PRESSURE
3.1 TURBINE FOLLOW TF A N N N Y N
CNTRL

PPESSURE
3.2 RUNBACK + TURBINE FOLLOW A N N N Y Y
CNTRL

To Turbine 4 COORDINATED MASTER CONTROL CMC A LOAD CNTRL Y Y Y N N To Combustion Control

(Load set point)
 CMC – TURBINE FOLLOW MODE
Runups
AUTOMATIC Increase CMC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES MEGAWATTS
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase
MW
Block Decrease
PT FW STEAM FLOW
A Set point

- +

∑ CMC Boiler Turbine

pressure PID PID Follow PID Follow
Controller Controller Controller
F(x)

Y
0 ∑ ∑
T1 A Y N
N
T3 Y
N
T4
MODE OF OPERATION
∑ N
S. NO. MODE
BOILER
TURBINE T1 T2 T3 T4 T5 Y
MASTER T5
LAG
1 MANUAL MAN M LOAD CNTRL N N N N N

Y 2 BOILER FOLLOW BF A LOAD CNTRL N N N N N Boiler

N
T2 T A Master
PRESSURE
3.1 TURBINE FOLLOW TF A N N N Y N
CNTRL

PPESSURE
3.2 RUNBACK + TURBINE FOLLOW A N N N Y Y
CNTRL

To Turbine 4 COORDINATED MASTER CONTROL CMC A LOAD CNTRL Y Y Y N N To Combustion Control

(Load set point)
 CMC – RUNBACK + TURBINE FOLLOW MODE
Runups
AUTOMATIC Increase CMC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES MEGAWATTS
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase
MW
Block Decrease
PT FW STEAM FLOW
A Set point

- +

∑ CMC Boiler Turbine

pressure PID PID Follow PID Follow
Controller Controller Controller
F(x)

Y
0 ∑ ∑
T1 A Y N
N
T3 Y
N
T4
MODE OF OPERATION
∑ N
S. NO. MODE
BOILER
TURBINE T1 T2 T3 T4 T5 Y
MASTER T5
LAG
1 MANUAL MAN M LOAD CNTRL N N N N N

Y 2 BOILER FOLLOW BF A LOAD CNTRL N N N N N Boiler

N
T2 T A Master
PRESSURE
3.1 TURBINE FOLLOW TF A N N N Y N
CNTRL

PPESSURE
3.2 RUNBACK + TURBINE FOLLOW A N N N Y Y
CNTRL

To Turbine 4 COORDINATED MASTER CONTROL CMC A LOAD CNTRL Y Y Y N N To Combustion Control

(Load set point)
 CMC – COORDINATED MASTER CONTROL
Runups
AUTOMATIC Increase CMC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES MEGAWATTS
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase
MW
Block Decrease
PT FW STEAM FLOW
A Set point

- +

∑ CMC Boiler Turbine

pressure PID PID Follow PID Follow
Controller Controller Controller
F(x)

Y
0 ∑ ∑
T1 A Y N
N
T3 Y
N
T4
MODE OF OPERATION
∑ N
S. NO. MODE
BOILER
TURBINE T1 T2 T3 T4 T5 Y
MASTER T5
LAG
1 MANUAL MAN M LOAD CNTRL N N N N N

Y 2 BOILER FOLLOW BF A LOAD CNTRL N N N N N Boiler

N
T2 T A Master
PRESSURE
3.1 TURBINE FOLLOW TF A N N N Y N
CNTRL

PPESSURE
3.2 RUNBACK + TURBINE FOLLOW A N N N Y Y
CNTRL

To Turbine 4 COORDINATED MASTER CONTROL CMC A LOAD CNTRL Y Y Y N N To Combustion Control

(Load set point)
CMC Graphic - 1
CMC Graphic - 2
Fuel Flow Control - 1
Fuel Flow Control - 2
Fuel Flow Control - 3
Air Flow Control - 1
Air Flow Control - 2
Air Flow Control - 3
Logic Description of CMC
CALORIFIC VALUE FACTOR CALCULATION
STEAM FLOW TOTAL COAL FLOW

PT FW

F(x)
NUM

DEM

LAG

LAG

x
CV FACTOR

CV CORRECTED TOTAL COAL FLOW

Combustion control
Air/fuel interlock :

In order to prevent a deficiency of air, a typical air/fuel interlock is implemented which

takes care of in case of an increasing firing demand that the fuel lags the air and , in
case of a decreasing firing demand that the fuel leads the air.
Combustion control
Air/fuel interlock :
Firing
demand
From
Air
control system
From
Fuel
control system

To To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Equilibrium
Firing
demand
50 % From
Air
control system
From
Fuel
control system

50 % 50 %

To 50 % 50 % 50 % 50 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Increase in firing demand
Firing
demand
60 % From
Air
control system
From
Fuel
control system

50 % 50 %

To 50 % 60 % 60 % 50 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Increase in Air demand
Firing
demand
60 % From
Air
control system
From
Fuel
control system

50 % 50 %

To 50 % 60 % 60 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Increase in Air flow
Firing
demand
60 % From
Air
control system
From
Fuel
control system

55 % 50 %

To 50 % 60 % 60 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Increase in Fuel demand
Firing
demand
60 % From
Air
control system
From
Fuel
control system

55 % 50 %

To 55 % 60 % 60 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Increase in Fuel demand & Air flow
Firing
demand
60 % From
Air
control system
From
Fuel
control system

60 % 55 %

To 60 % 60 % 60 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Equilibrium
Firing
demand
60 % From
Air
control system
From
Fuel
control system

60 % 60 %

To 60 % 60 % 60 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Increase in firing demand

Firing demand

Air flow α

β
Fuel flow
α = β

Time
Combustion control
Air/fuel interlock : Decrease in firing demand
Firing
demand
40 % From
Air
control system
From
Fuel
control system

60 % 60 %

To 60 % 40 % 40 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Decrease in fuel demand
Firing
demand
40 % From
Air
control system
From
Fuel
control system

60 % 60 %

To 40% 40 % 40 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Decrease in fuel flow & air demand
Firing
demand
40 % From
Air
control system
From
Fuel
control system

60 % 50 %

To 40% 40 % 40 % 50 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Decrease in fuel flow & air demand
Firing
demand
40 % From
Air
control system
From
Fuel
control system

50 % 40 %

To 40% 40 % 40 % 40 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Equilibrium
Firing
demand
40 % From
Air
control system
From
Fuel
control system

40 % 40 %

To 40% 40 % 40 % 40 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Decrease in firing demand

Firing demand

Air flow α

β
Fuel flow
β > α

Time
Combustion control
Air/fuel interlock : Disturbance on air side
Firing
demand
40 % From
Air
control system
From
Fuel
control system

20 % 40 %

To 20% 40 % 40 % 40 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Disturbance on air side
Firing
demand
40 % From
Air
control system
From
Fuel
control system

20 % 20 %

To 20% 40 % 40 % 40 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : disturbance in air flow
Question : what will the fuel flow do ?

Firing demand

Air flow α

β
Fuel flow
β α

Time
Combustion control
Air/fuel interlock : disturbance in air flow
Answer : fuel flow will decrease with the same slope=speed

Firing demand

Air flow α

β
Fuel flow
β = α

Time
Combustion control
Air/fuel interlock : Equilibrium
Firing
demand
40 % From
Air
control system
From
Fuel
control system

40 % 40 %

To 40% 40 % 40 % 40 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Disturbance on fuel side
Firing
demand
40 % From
Air
control system
From
Fuel
control system

40 % 60 %

To 40% 40 % 40 % 40 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : Disturbance on fuel side
Firing
demand
40 % From
Air
control system
From
Fuel
control system

60 % 60 %

To 40% 40 % 40 % 60 % To
Fuel Air
control system control system
Combustion control
Air/fuel interlock : disturbance in fuel flow
Question : what will the air flow do ?

Firing demand

Air flow

β
Fuel flow
β α

Time
Combustion control
Air/fuel interlock : disturbance in fuel flow
Answer : air flow will increase with a smaller slope=lower speed.

Firing demand

α
Air flow

β
Fuel flow
β > α

Time
Combustion control
Air/fuel interlock summary

If the firing demand increases, first the air demand increases and if the air
flow increases than the fuel flow demand increases and so the fuel flow.

If the firing demand decreases, first the fuel demand decreases and if the
fuel flow decreases than the air demand decreases and so the air flow.

If a disturbance decreases the air flow the fuel demand decreases
automatically.

If a disturbance increases the fuel flow the air demand increases
automatically.

Air flow is somewhat ‘slower’ than the fuel flows because of the size of the
controlling device (dampers, fan speed) and different pressure levels and
media
 Unit
Coordinated Control
(UCC)

An
Emerson philosophy
Introduction

The Unit Coordinated Control (UCC) provides a coordinated front-end control strategy
that ties boiler and turbine controls.

UCC generates and regulates the set-point for unit load (MW).

Unit load set-point may be generated from local operator entry, remote
increase/decrease contact/pulse inputs or internally generated contingencies such as
runbacks and rundowns.

The UCC controls unit load (MW) and throttle pressure by sending parallel demand
signals to the boiler and turbine control loops through respective Boiler and Turbine
Master M/A stations.

The Boiler Master demand is used as a feed forward signal to the loops controlling
feed-water, fuel and air flow to improve unit response to load changes.

The Turbine Master demand controls the turbine control valves by sending an analog
output signal to turbine controls.

The operator interface to the UCC is via UCC graphic and associated pop-up windows
which are accessed at an operator station.
 UCC configuration
Principal modes

Base mode

Boiler follow modes - Pressure on Boiler

Boiler follow 1 (BF1) mode

Boiler follow 2 (BF2) mode

Turbine follow modes - Pressure on Turbine

Turbine follow 1 (TF1) mode

Turbine follow 2 (TF2) mode

Coordinated modes

Coordinated Boiler follow (CBF) mode - Megawatts on Turbine

Coordinated Turbine follow (CTF) mode - Megawatts on Boiler

Remote Mode – Load set point from remote

URO Mode - Advanced Control
UCC modes – Load Ramper scheme
UCC modes – Typical scheme
CBF

CTF

TF BF
 UCC configuration and mode selection
Runups
AUTOMATIC Increase UCC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase MEGAWATTS
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC mode – BASE [BA]
Runups
Increase UCC
AUTOMATIC Rundowns
DISPATCH TRACKS Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease MEGAWATTS Block Increase MEGAWATTS
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC ‘one’ mode – Boiler Follow 1 [BF1]
UCC Runups
AUTOMATIC Increase TRACKS Rundowns
DISPATCH TURBINE Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease Block Increase MEGAWATTS
MASTER
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC ‘one’ mode – Turbine Follow 1 [TF1]
UCC Runups
AUTOMATIC Increase TRACKS Rundowns
DISPATCH BOILER Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease Block Increase MEGAWATTS
MASTER
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC ‘two’ mode – Boiler Follow 2 [BF2]
Runups
AUTOMATIC Increase UCC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase MEGAWATTS
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC ‘two’ mode – Turbine Follow 2 [TF2]
Runups
AUTOMATIC Increase UCC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase MEGAWATTS
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC ‘two’ mode – Coordinated Boiler Follow [CBF]
Runups
AUTOMATIC Increase UCC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase MEGAWATTS
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
 UCC ‘two’ mode – Coordinated Turbine Follow [CTF]
Runups
AUTOMATIC Increase UCC Rundowns
DISPATCH RATE SETTER Runbacks CONTINGENCIES
PRESSURE SYSTEM (ADS) Decrease LOAD SETTER Block Increase MEGAWATTS
Block Decrease
PT MW

A Set point

Turbine Boiler
PID Throttle PID Turbine Throttle PID Boiler PID
Pressure Megawatt Pressure Megawatt
Controller Controller Controller Controller

T1 T2 T3 T4

MODES OF OPERATION
∑ MODE BOILER TURBINE T1 T3 T4 ∑
T2
BASE BA M M X X X X
STARTUP/SHUTDOWN SS A M 0 0 0 0
BOILER FOLLOW BF1 A M X X 1 0
TURBINE FOLLOW TF1 M A 1 0 X X
Turbine COORD BOILER FOLLOW BF2 A A 0 0 1 0 Boiler
Master T COORD TURBINE FOLLOW TF2 A A 1 0 0 0 T A Master
A COORD BOILER FOLLOW W/MW CBF A A 0 1 1 0
COORD TURBINE FOLLOW W/MW CTF A A 1 0 0 1
ADVANCED CONTROL URO A A X X X X
M - Manual X - Don’t Care 0 - Open
To Turbine Control A - Auto 1 - Closed To Combustion Control
Typical UCC graphic
Remote Mode
Enables remote dispatcher to control load through UCC.
Operator can select Remote if UCC is in any of BF2, TF2, CBF or CTF mode from
UCC graphic.

Remote mode is deselected automatically if:

UCC is rejected to BF1, TF1 or Base mode.

Block increase, Block decrease , Rundown or Runback occurs.

Operator changes UCC mode.

UCC maximum or minimum limit is reached.

Operator requests for local mode.
Pressure Mode

Fixed pressure

Sliding pressure
Sliding pressure implementation

 Pressure is linear with megawatts at constant valve demand

 Linearized turbine: megawatts linear with demand at rated pressure
 Pressure can slide along any one selected valve point
 Valve points are usually in the 75% to 95% load range
 Floor pressure is usually ~ 40% of rated pressure
 In the sliding pressure region the turbine demand equals the valve
point value - valves stay constant
 Once sliding pressure reaches rated pressure the turbine demand
increases - valves begin to open
 Once sliding pressure reaches the floor pressure the turbine demand
decreases - valves begin to close
Typical turbine demand on sliding pressure
100% RATED 100% DEMAND
Sliding pressure
curve
programmed in
the f(x)
V
A
75% DEMAND L
66.6% RATED V
E

50% RATED 50% DEMAND

D
ACTUAL E
40% RATED VALVE M
DEMAND A
N
D

Sliding pressure
region

0 30% 50 75% 100

LOAD (%)
Pressure set point correction to turbine
Load TP
Demand RATED TP
SETPOINT

DEM NUM

DIVIDE
The multiplier
keeps the
relationship AT RATED = 1
between load
demand and
turbine demand
constant
MULTIPLIER As throttle pressure set point
moves away from rated pressure, a
correction is applied to the turbine
demand

TO TURBINE TO PRESSURE
MASTER CONTROLLER
Sliding pressure correction on turbine
Load TP set point
Demand (sliding) RATED TP

F(X)
DEM NUM

DIVIDE
The multiplier
keeps the
relationship AT RATED = 1
between load
demand and
turbine demand
constant
MULTIPLIER As throttle pressure set point
moves away from rated pressure, a
correction is applied to the turbine
demand

TO TURBINE TO PRESSURE
MASTER CONTROLLER
Sliding pressure on a 75% valve point
100% RATED

T
Sliding pressure
H
curve
R
programmed in
O
the f(x)
T
T 66.6% RATED
L
E Valves wide open

50% RATED

P
R 40% RATED
E 75% valve point
S
S At rated pressure
U this valve demand
R results in 75% load
E Minimum (floor)
pressure

0 30% 50 75% 100

LOAD (%)
Doing the math at 50% load demand
Load TP set point
Demand (sliding) RATED TP

66.66 100
50
F(X)
DEM NUM

DIVIDE
The multiplier
keeps the
relationship 1.5
between load
demand and
turbine demand
constant
MULTIPLIER As throttle pressure set point slides
on the valve curve the result is a
constant output from the multiplier
- in this case 75% valve point - until
75
a limit is reached

TO TURBINE TO PRESSURE
MASTER CONTROLLER
Turbine valve demand on a 75% valve point
100% RATED 100% DEMAND
Sliding pressure
curve
programmed in
T the f(x)
H
R V
O A
75% DEMAND L
T
T 66.6% RATED V
L E
E

50% RATED 50% DEMAND

D
ACTUAL E
P VALVE
R 40% RATED M
DEMAND A
E
S N
S D
U
R
E Sliding pressure
region

0 30% 50 75% 100

LOAD (%)
Contingencies
Contingencies-1
BLOCK INCREASE (BI)

Occurrence of Block Increase prevents UCC demand from increasing when in auto
mode. Block increase occurs when process reaches a maximum or a process value is
much less than demand.

The unit load is limited because one or more of the key auxiliaries is at a maximum or
the process value is significantly less than demand. BI signals are based on Fuel,
Feed water ,Air or Throttle pressure.

The cause of block increase will be highlighted on the graphics.
Contingencies-2
BLOCK INCREASE (BI)

Occurrence of Block Increase prevents UCC demand from increasing when in auto
mode. Block increase occurs when process reaches a maximum or a process value is
much less than demand.

The unit load is limited because one or more of the key auxiliaries is at a maximum or
the process value is significantly less than demand. BI signals are based on Fuel,
Feed water ,Air or Throttle pressure.

The cause of block increase will be highlighted on the graphics.

BLOCK DECREASE (BD)

Occurrence of Block Decrease prevents UCC demand from decreasing when in auto
mode. Block decrease occurs when process reaches a minimum or a process value is
much greater than demand.

The unit load is limited because one or more of the key auxiliaries is at a minimum or
the process value significantly exceeds the demand. BD signals are based on Fuel,
Feed water ,Air or Throttle pressure.

The cause of block decrease will be highlighted on the graphics.
Contingencies-3
RUNDOWN

UCC rundown occurs when a condition exists where one or more of the fuel, air or
feed water are at maximum or the associated demand is significantly greater than the
actual process value.

There is an additional rundown due to high furnace pressure.

The rundown will continue to reduce UCC demand at a tunable rate until rundown
condition clears.

On a rundown UCC target is forced to track UCC demand and UCC is rejected to local
mode if in remote.

The cause of rundown are highlighted on the UCC graphics.
Contingencies-4
RUNBACK

UCC runback occurs due to loss of any one of critical boiler/turbine auxiliaries, for e.g.
FD/ID/PA fan, BFP or coal mills etc. .

The runback targets and rates are adjustable for each runback depending on capacity
loss due to loss of the auxiliary.

On a runback UCC target is forced to track UCC demand and throttle pressure control
is rejected to constant pressure control if in sliding pressure mode. UCC is rejected to
local mode if in remote.

On completion of runback UCC is rejected to TF2 mode.

The cause of runback will be highlighted on the graphics.
Questions ??