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

INPUT PROCESS OUTPUT

PROCESS

CONTROLLED LOAD MANIPULATED

VARIABLE VARIABLE VARIABLE
•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
 Turbine Follow Mode Continued..

MS Pressure
Actual
PR. Tx.
GRID
Boiler Pr. Set Point
EHG
PI Controller

Fuel & Air Turbine Generator

 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 MS PRESSURE

Grid
MS Pr. Set point
PD

BOILER Turbine

PID
EHG PI Cntrlr G

+ +
Fuel Contl Air Contl
LOAD

Load Set Point

Boiler Demand
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 125 MW
Tripping (If std. by Does Not
take start)
One FD fan / One ID fan 125 MW
Tripping
One PA fan / One Coal Mill 168 MW
Tripping
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

(tmi , dtu)
dt Upper temp. margin
Present operating
Point (instantaneous)

(tmi , dti) tm
Lower temp. margin

(tmi , dtL)
 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.
 Generation of CMC Unit Load Demand
From Unit Load Set Point

Gen MW

PB/VPC MAX To next slide

2 ADD MIN

CMC in
Tracking for service MAX S.P. MIN S.P.
Runback / Freq.
Rundown Or Influence Defeat Switch
no CMC
 Generation of CMC Unit Load Demand
From Unit Load Set Point
Contd..
Ramp
From Previous slide
1 1
MIN 2 2
Block
CMC demand
Grad
Runback/ Rundown
Limit
EHG Hold
Up/Down Dir
Block
Load Rate SP
TSC Rate Min

Runback/Rundown Rate
 Generation of Boiler Master Set Point
From CMC Demand

For Changing load

1 D

2
ADD Boiler
Master
Load. Dev
ADD
Steam PID
Pr. Dev.

D
For Steady State
 Generation of Turbine Master (EHG) Set
Point From CMC Demand

Dead Time 3
Delay
2

Pr. Dev.
ADD EHG

3 +10MW +ve Limit

+
MAX
2 - PID / P

MIN -ve Limit

-10MW
 Load Rate Circuit

PB/VPC Load Rate

SP Stn
1
MIN

TSC Rate Load Rate

2
Runback Rate 1
Rundown Rate 2

Runback / Rundown
In Action
Runback in action