Cmc philosophy

…Message Box ( Arial, Font size 18 Bold)
Presentation Title ( Arial, Font size 28 )
Date, Venue, etc..( Arial, Font size 18 )
Close Loop control and CMC
3rd APRIL, 2015
Amara Balakrishna Chaitanya
Mohan Kasilingam
Vikash Kumar Upadhyay

SAFETY
…Message Box (Arial, Font size 18 Bold)
Safety Vision: To be a leader safety excellence in the global power and energy
business.
Safety Principles: TATA Power believes that good safety is good business which helps to
sustain world class business performances. Safety principle provides direction and focus
to our occupational health and safety program for achieving and sustaining safety
excellence.
Plan
Improve corrective action Do
Check

1
•Boiler Auto Loop
2
•Turbine Auto Loop
3
•BOP Auto Loops

Introduction of key parameters
• APID : Advance proportional-integral-derivative controller (APID controller) is
a control loop feedback mechanism(controller) widely used in industrial control
systems. APID controller calculates an error value as the difference between a
measured process-variable(PV) and a desired setpoint(SP). The controller attempts
to minimize the error by adjusting the process through use of a manipulated variable.
• Air-Fuel ratio: Air-Fuel ratio is important to maintain air-rich environment in furnace.
• Auto-Manual station : It is a interface for operator to put any system into Auto or
Manual.
320
400
491
531
561
610
320
400
491
531
561
610
320
400
491
531
561
610
320
400
491
531
561
610
0
100
200
300
400
500
600
700
10 36 66 79 89 105
TotalAirFlow(Tph)
Coal Flow(Tph)
Air vs Fuel

Introduction of key parameters (cont..)
• Bias: It is the deviation given to any demand to generate required output.
• Bed temperature trim factor: It use to trim PA demand as per mid DP.
• CV factor :95 TPH of Coal = 495 TPH Steam flow
{(95/495)* Present MS Flow}/Present Coal Flow
Limits: 0.5 – 1.5
• DMS:
• TMS
0.899 0.899
1
1.1
0.899 0.899
1
1.1
0.899 0.899
1
1.1
0.899 0.899
1
1.1
0
0.2
0.4
0.6
0.8
1
1.2
1200 800 500 300
TrimFactor
MD DP
Bed temp trim factor

Introduction of key parameters (cont..)
• Dead band: If Output co-ordinate is constant with respect to Input
Co- ordinate
• Limiter: Two Type Max Limiter and Min Limiter.
• O2 trim factor : Maintain O2 Percentage.0.8
1
1.2
0.8
1
1.2
0.8
1
1.2
0.8
1
1.2
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 50 100
O2Trimfactor
Output of APID
O2 Trim Factor

Boiler Follow mode
Boiler
Controls
Throttle
Pressure
DCS
Varying
coal Feed
Turbine
Controls
Load(MW) DEH PC
Varying
GVs

Turbine Follow mode
Turbine
Controls
Throttle
Pressure
DEH PC
Varying
GVs
Boiler
Controls
Load(MW) DCS
Varying
coal Feed

Boiler
Follow
Turbine
Follow
Co-ordinated
Master
Control

Co-ordinated Master Control (CMC)

Boiler master

Boiler
Fuel Cycle
Air cycle
Furnace
Draft Control
PA Control
PA header PA Flow
SA Control
SA Header SA Flow
O2 control
Fuel Master

Flow Limits :245 to 310
TPH
Bed Temp trim factor
(0.899-1.10)
U beam trim factor
(871- avg ubeam temp)
APIDXf(X)1
240 250
265
295
315 325
0
50
100
150
200
250
300
350
32 48 60 80 100 124
PAFlow
Coal Flow
F(x) to APID
PA flow control
2
1
0.667
2
1
0.667
2
1
0.667
2
1
0.667
0
0.5
1
1.5
2
2.5
0.5 1 1.5
F(X)output
CV factor

O2 MIN: 1.5
13
8.35
5
4.1 3.9 3.5
0
2
4
6
8
10
12
14
52 196 368 441 459 500
CalculatedO2setpoint
Steam flow
O2 control

320
400
491
531
561
610
320
400
491
531
561
610
320
400
491
531
561
610
320
400
491
531
561
610
0
100
200
300
400
500
600
700
10 36 66 79 89 105
TotalAirFlow
Coal Flow
F(x) to APIDCV factor
multiplication
factor1
0.8
1
1.2
0.8
1
1.2
0.8
1
1.2
0.8
1
1.2
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 50 100
O2Trimfactor
Output of APID
Total Air(320to 640)
Max flow to BAC
and DCF=80 Tph
SA flow control

10
36
66
79
89
105
10
36
66
79
89
105
10
36
66
79
89
105
10
36
66
79
89
105
0
20
40
60
80
100
120
320 400 491 531 561 610
Coalflow
Total Air Flow
1.25
1
0.833
1.25
1
0.833
1.25
1
0.833
1.25
1
0.833
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 50 100
O2Trimfactor
Output of APID
CV1
FUEL FLOW (FROM FUEL VS AIR FLOW)* O2 TRIM*1.1*CV FACTOR)
Fuel flow control

Boiler Master feed forward control
APID
Pressure SP –
actual throttle
pressure
3.33/((No. Of DCF)*CV factor)
Feed forward to DCF speed
control

HP-LP Bypass

HP Bypass PCV
Start up HP bypass SP
Cold 40
Warm 60
Hot 70
Extreme hot 80
GCB open
• Start up selection
GCB close
• Operator SP selection: HP bypass final SP = Operator SP + 5 kg/cm2
• Calculated SP selection: HP bypass final SP = Calculated SP + 5 kg/cm2
Calculated SP
• Rate of rise in pressure > 4%/min (5.6 kg/cm2/min)  HP bypass opens if in auto
• Rate of rise > 8%/min (11.2 kg/cm2/min)  HP bypass is forced to auto and will open

HP Bypass TCV
• Spray control types: Cascade mode, Heat balance mode, Normal CV operation
• Heat mass balance mode: Qspray = QMS * (HMS-HHPBP O/L steam) / (HHPBP O/L steam-
Hspray)
• QMS = Volume on basis of HPBP PCV * Calculated density based on MS hdr
temp and MS hdr pressure.
• Cascade mode: APID SP is given by operator/calculated.
• PV is temperature of HP bypass O/L
• FF is our heat balance mode O/P.
• Normal CV operation: Operates only on SP and PV.

LP Bypass PCV
Start up LP bypass
SP
Cold 6
Warm 6.5
Hot 7
Extreme
hot
7.5
>
Calculated start up set point
HPT first stage pressure F(x)
+1.5 kg/cm2
GCB close
LPBP PCV final SP
1
27.5
30
0
10
20
30
40
0 95.5 110
F(x)output
HPT first stage pressure

LP Bypass TCV
• Spray control types: Cascade mode, Heat balance mode, Normal CV operation
• Heat balance mode: Qspray = QHRH * (HHRH-HLPBP O/L steam) / (HLPBP O/L steam-Hspray)
• QHRH = Volume on basis of LPBP PCV * Calculated density based on HRH hdr
temp and HRH hdr pressure.
• Cascade mode: APID SP is operator SP/calculated
• PV is temperature of LP bypass O/L
• FF is our heat balance mode O/P.
• Normal CV operation: Operates only on SP and PV.

Thank you !

Limits : 40%, 100%
Operating range:40% to 70%
Operating range: 0% to 75%.
-6
-4
-2
0
2
4
6
-36 -30 -1 1 29.5 30
SPtoAPID
ID IGV DEMAND -70
F(x)
Furnace draft control

Limits : 0, 100%
Operating range: 0% to 65%
-6
-4
-2
0
2
4
6
-36 -30 -1 1 29.5 30
SPtoAPID
PA IGV DEMAND -70
F(x)
PA header pressure control

Limits : 0, 100%
Operating range: 0% to 65%
-6
-4
-2
0
2
4
6
-36 -30 -1 1 29.5 30
SPtoAPID
SA IGV DEMAND -70
F(x)
SA header pressure control

Boiler
SH Temp
Stage 1 Stage 2
RH Temp
RH
Bypass
RH spray

508
496
465
508
496
465
508
496
465
508
496
465
440
450
460
470
480
490
500
510
520
271 360 495
CalculatedStage-Itemperature
Main Steam Flow
SH stage-I spray control

Set point of 2nd stage depend on two situation.
1) GCB Open .
2) GCB Close .
CASE:1
COLD START-UP: 280 C
WARM START-UP:400 C
HOT START-UP: 440 C
EXT HOT START-UP: 510 C
CASE :2
F(X){DRUM PR VS SAT-TEMP}+50 C(DEG OF SUPERHEAT) 
F(X){MAIN STEM FLOW VS TEMPERATURE)  > SP
SH stage-II spray control

RH temperature control
Set point of 2nd stage depend on two situation.
1) GCB Open .
2) GCB Close .
CASE:1
COLD START-UP: 220C
WARM START-UP:330 C
HOT START-UP: 410 C
EXT HOT START-UP: 480 C
CASE :2
F(X){CRH PR VS SAT-TEMP}+50 C(DEG OF SUPERHEAT) 
(RH O/L TEMP +1) 
(537 C) 
> SP
<
81.33 99.97
151.8
179.9
212.8
234
264
286.3
311.7
343.2
375.6
0
50
100
150
200
250
300
350
400
0.50 1.032 5.099 10.19 20.39 30.59 50.98 71.38 101.9 152.9 224
Saturationtemperature
CRH pressure
CRH pressure vs sat temp

Turbine
Feed cycle
Drum level
1E 3E
B.F.P. Scoop
Condensate
cycle
D/A
pressure
D/A level CEP R/C H/W level
Cond.
MAKE-up
CEP Reject

COMPENSATE LEVEL: [H(DWR-DS)-DP*DWC)]/(DW-DS)
H=STUD DISTANCE( DRUM= 900 MM)
DWR=AVG DENSITY OF REF COLUMN
DWC=DENSITY OF CALIBRATION WATER
DW=DENSITY OF DRUM WATER
DS=DENSITY OF DRUM STEM
COMPENSATED FLOW VALUE= {(D.P.)^(1/2)}CONSTANT.
NOTE: SATURATION PRESSURE AND SATURATION TEMPERATION TRIMM FACTOR ALSO
PLAY ROLE.
Drum level control

Drum level control (cont..)

COMPENSATE LEVEL: [H(DWR-DS)-DP*DWC)]/(DW-DS)
H=STUD DISTANCE( D/A= 2800 MM)
DWR=AVG DENSITY OF REF COLUMN
DWC=DENSITY OF CALIBRATION WATER
DW=DENSITY OF DRUM WATER
DS=DENSITY OF DRUM STEM
COMPENSATED FLOW VALUE= {(D.P.)^(1/2)}CONSTANT.
NOTE: SATURATION PRESSURE AND SATURATION TEMPERATURE TRIM FACTOR ALSO
PLAYS ROLE.
Deaerator level control

Turbine
HPLP
By-pass
APRDS
Pressure
MS CRH
Temp
GS
Pressure
I/L Leak-off
Temp
HP LP
Heater
level

Gland steam control

Hot well level control

CEP recirculation flow

Aux steam pressure and temp control

Deaerator pegging control

0
50
100
150
200
250
300
350
400
Saturationtemperature
Drum pressure
Drum pressure vs sat temp

505
510
515
520
525
530
535
540
545
550
555
200 300 550
CalculatedMStemperature
Main steam flow
MS flow vs MS temp

20 20
0 0
-20 -20
-25
-20
-15
-10
-5
0
5
10
15
20
25
47 49 49.5 50.5 51 53.2
OffsettopresentMW
Frequency
Frequency influence
Frequency influence to generate Load SP

Run back
Equipment Number Load capability Run back SP Run back Rate
ID fan 2*80 160 80 200 MW/min
PA fan 2*80 160 80 200 MW/min
SA fan 2*80 160 80 1000 MW/min
BFP 2*80 160 80 1000 MW/min
DCF 5*32 160 160-n*32 100 MW/min
Min (HMI Load SP, Run back SP) Load SP
Boiler Load Index (BLI) = Steam flow / 3.2 ;(Conversion of steam flow to MW)
Run
back SP
limiter
BLI*1.05 + TSE (16.66)  Max limit in MW
BLI*0.75 - TSE (16.66)  Min limit in MW

MS pressure correction to generate TG load SP
16
8
0 0
-8
-16
-20
-15
-10
-5
0
5
10
15
20
-5 -3 -1 1 3 5
MWdeviationtoTG
Throttle pressure SP - actual
MS pressure correction

THANK YOU
Journey Continues…

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