COORDINATE CONTROL SYSTEM

COORDINATE CONTROL SYSTEM

PRESENTATION BY
ANIL KUMAR VERMA
INTRODUCTION
In a Thermal Power Unit operation the critical internal unit parameters related to production are MW, Main steam
pressure. The critical external parameter is frequency of the network. In a boiler the steam production depends on
combustion control (Fuel control and Air flow control). So one of the unit parameters MW or main steam pressure must be
used for Boiler control.

Turbine Generator produces electrical output (MW) proportional to steam input to turbine. The turbine control system
varies steam input to turbine to achieve unit parameter MW or Main steam pressure.

The network stability always depends on the balance of power production and power consumption. Any unbalance in the
power production and power consumption leads to change in the frequency of operation in the direction of attaining
natural stabilization i.e., balancing of power consumption with power production. However as the capacity of this
stabilization is limited for the network for stability, proportional frequency correction is given in turbine control system to
vary the power production in the direction to achieve stability of network.

The 5% regulation used generally in thermal power units, gives 100% load correction for 5% frequency disturbance in the
network. This is selected mainly to achieve network stability within the rotating machines speed variation of 95% to
105%. At 110% Turbo generators have over speed trip protection.
GRID FREQUENCY
In a network the power production or power consumption can change due to several reasons like units tripping on some
internal problems or load breaker tripping. So to ensure the stability of network it is necessary to have frequency
regulation in Turbine control. It is also to be emphasized here that if only few units in the network implement the
frequency control the total disturbance in the network will be passed on to the units having regulation by the many units
which do not have regulation. Frequency is network parameter which cannot be controlled by few units in the network.

TURBINE
In Thermal Power Units the Turbines are quick responding components and Boilers are having transport lag and Thermal
inertia and hence slowly respond with variation in command. So the Turbine will be able to meet MW demand or main
steam pressure set value quickly by positioning the control valves of Turbine to the required values.
Turbine will be able to maintain only one unit parameter MW or main steam pressure.
The other is to be controlled, naturally by the boiler
MODES
The modes of operating the unit are named as

 1.turbine follow mode and

 2.boiler follow mode.

 3. Coordinate control system

TURBINE FOLLOW

In Turbine follow mode Turbine maintains throttle steam pressure. The MW depends on the steam output from the
Boiler. The variations in the Boiler steam output will be resulting variations in MW output. Boiler steam output variations
can result from changing Calorific values of coal etc. Turbine follow mode gives more stability to unit by controlling
main steam pressure perfectly and quickly which is a very important unit parameter.

If Boiler combustion controls fuel and air are in Auto, corrective actions will be taken by boiler controllers to change
combustion to give desired steam for the set MW. These responses will be slow when compared to turbine responses. So it
may be reemphasized that this mode of operation gives maximum stability to unit operations with slow response to grid
requirements by initiating combustion controls first and turbine valves positioning after steam production.

BOILER FOLLOW
 In Boiler follow mode Turbine maintains MW demands and Boiler maintains main steam pressure.   Turbine will be
responding to grid requirement  firstly because of droop characteristic set in DEH and Boiler will be following to maintain
main steam pressure if combustion controls are in Auto. This mode of operation gives maximum stability to network
because MW requirements are met by Turbine quickly and lesser importance to unit stability, because the action by
Turbine will be disturbing main steam pressure. If all units in the network do not implement 5% regulation then the
network disturbances will be passed on to the units in Boiler follow mode disturbing their MW level of operation often.
Boiler combustion controls must be kept in Auto in this mode of operation which will be taking main steam flow and main
steam pressure error as inputs for control. The main steam pressure is the final trimming signal to boiler for boiler follow
mode of operation. Response of Turbine to grid requirements is quickly perceived by boiler controls through main steam
flow variations. Finally Boiler controls ensure the set throttle pressure.

CO-ORDINATED CONTROL MODE

In coordinated mode of operation unit load dictator (ULD)/master control station sets MW set point which will be
pursued by combustion controls by taking main steam pressure error as final trimming input signal. Operator can not
change the load set point in CCS mode. Turbine will be controlling the MW at the set point or changes in grid frequency
will be leading to changes in the MW. Main steam pressure error will have proportional influence for stability of the unit.
Boiler will be trying to control main steam pressure.

Coordinated mode and boiler follow mode are similar in response except that base signal required for boiler combustion
control is MW set point in coordination mode and main steam flow signal in Boiler follow mode.

Turbine & Boiler combined control

UNIT CAPABILITY
Unit capability is capacity of the unit to produce the MW at that time. Unit capability signal depends on the number of
Auxiliaries in service and their contribution is expressed as MW signal which they can support. For example if four mills
are required to produce 300MW each mill capability will be taken as 75 MW approximately. The capability will be
computed from each type of Auxiliaries and minimum of all these will be the unit capability. On any running Auxiliary
tripping, unit capability signal will be dependent on the type of auxiliary tripped.
UNIT RUNBACK
 In Runback mode Boiler combustion controls give commands in proportion to unit capability and boiler will be coming to
the state of steady combustion and hence will be stabilizing. Turbine will be controlling main steam pressure as this will
give maximum stability to the unit. Runback mode gives highest stability to unit because unit has gone to instability (ex.
Mill/BFP/ID/FD tripped) this Runback mode gets selected automatically and ensures stability.
Whenever unit capability is less than unit load dictator (ULD) command the Runback mode sets in automatically.
MODES

1   CCS control input

After a steam turbine is grid-connected, the CCS mode can be put in. When the following conditions are met, the CCS
mode can be put in:
The turbine has been grid-connected and runs under “AUTO” control mode;
CCS system sends a “CCS REQ” signal to DEH and the signal is all right. The instruction from CCS is also all right
No TPC protection action;
No load limit action;
No runback action.
CCS CONTROL
DEH can cooperate with CCS to complete the coordination control of unit and boiler. Under the CCS control mode, DEH
is one of the actuator of CCS. DEH automatically cancels the power control and, according to the instructions given by
CCS, control the opening of all valves. DEH can give a proper judgment or restriction to CCS instruction in terms of
higher limit, lower limit and rate of change.
It is required that during CCS input the “CCS CONTROL REQUEST” signal shall be normally available, otherwise, DEH
decides that CCS proper has cancelled it and as a result DEH changes from a CCS control mode to a valve position control
mode.
  When DEH receives the “CCS CONTROL REQUEST” signals, we can click the “CCS INPUT” button in the
“AUTOMATIC CONTROL” menu of OIS, and the menu will display “CCS INPUT”. Under the CCS control mode, the
DEH target is equal to the CCS setting value. At this point, the target follows the increase and decrease of CCS setting
signals and the actual load also changes accordingly.

2   CCS control canceling

When there are the following conditions, the CCS control mode will be cancelled:
Under manual mode;
CCS request signal  disappear;
Failure of demand from CCS;
TPC action;
High load restriction action;
Low load restriction action;
Operators cancel the mode;
Grid dis-connected;
RUNBACK action;
The steam turbine has tripped.
3.LOAD CONTROL ON CCS
   Under the CCS control mode, the target(%) is send from CCS, the opening of CV and ICV is controlled by CCS
demand. Operators are not allowed to operate high load and lower load limit. It is set up as 330MW and 8MW
automatically.

LEGENDS
A :target load
B :upper load limit
C :lower load limit
D :load change rate (%)/min
E :lockout increase/decrease
F : variable pressure operation
G :throttle pressure
M :speed control mode
N :turbine main control (valve position limit)
S :boiler main control (adjuster)
T :fuel main controller
ADS :automatic load dictation system (unit load master)
CODEMODE :coordination mode
TURBFLW  :turbine follow mode
BLRFLOW :boiler follow mode
BASEMODE :manual mode

THE MAIN FUNCTION OF MCS (Modulating Control System)

The unit parameter can be maintained automatically when the load is in the range of 30% to 100%.
The forming of the load instruction of the unit.
FM (frequency modulation) control.
Load instruction limitation
Runback (RB)
Runup and Rundown (RUP, RD)
Increase or decrease lockout of the load instructions
The operation of BM (Boiler main control) and TM (Turbine main control) under the BASE, BF, TF, and CCS
The switchover of BASE, BF, TF and CCS

THE FUNCTION OF CCS

1. Initiation of ULD (unit load dictation)
There is unit main control station “A” on OIS station. The target load dictation is from ADS (automatic dictation system)
when in automatic mode. If it is in manual mode, operator change the setting value of station A to send the target load
dictation. After being limited by amplitude and speed demands, target instructions have become into actual instructions,
being sent to steam turbine and boiler main control. When RD, RB or RUP happen, ULD will be in tracking mode.
2. FM control
When speed control method has been chosen in “M” station by operator, unit will be frequency modulated  once,
controlling steam turbine rotational speed to maintain the system frequency. ULD will track the actual power to avoid
internal disturbance at the time of switching. After the FM moment, system could back to ADS control smoothly.
3. Load limitation
The upper and lower limit of ULD can be adjusted in “B” & “C” station. When the ULD reached the limitation, it is
prevented from increasing or decreasing any more, with alarm signal sent out. When RD & RB happen, it can’t be limited
by lower limit, which will be amended by the actual ULD to realize the smooth transfer from RD & RB to coordinated
mode. When RUP happen, it can’t be limited by  upper limit, which will be amended by the actual ULD to realize the
smooth transfer from RUP to coordinated mode.
4. ULD change rate
When in normal working condition, ULD will be limited by the maximum change rate, which will be set in “D” by
operator. It can be set as follows

1. Normal load change rate :

           2.5%/min in variable pressure operation
           3%/min in constant pressure operation
2. Maximum load change rate :
          3.5%/min in variable pressure operation
          5%/min in constant pressure operation
5. RUNBACK
When one ID fan, FD fan, PA fan  trips or  one feed water pump trips and standby feed water pump refused to start and
ULD is larger than the load that single equipment can sustain then RB will happen. The new ULD equals the load that
single aux. equipment can sustain.
6. RUNDOWN
     When aux. equipments are running but actual flow quantity is less than required, such as

Feed water instruction is at upper limit but actual flow is lower than setting value by allowable deviation.
Fuel instruction is at upper limit but actual fuel is lower than setting value by allowable deviation.
FD fan instruction is at upper limit but actual air flow is lower than setting value by allowable deviation.
ID fan instruction is at upper limit but actual furnace pressure  is higher  than setting value by allowable deviation.
When “generator symmetrical overload output reduction” signal is sent.

     The result of RD is to make ULD decrease at some rate to make the ULD and the capability match well and maintain
system in normal condition.

7. RUNUPS
It is opposite to RD. RUP will happen when

Fuel instruction is at lower limit but actual fuel is higher than setting value by allowable deviation.
Feed water instruction is at lower limit but actual flow is higher than setting value by allowable deviation.
FD fan instruction is at lower limit but actual air flow is higher than setting value by allowable deviation.

8.Equipment Capability Limitation of ULD

          ULD lockout increase/decrease (load set point at “A” will           decrease/increase) in the following condition
1. Fuel rate is maximum/minimum.
2. Forced draft fan instruction is maximum/minimum.
3. FD fan air flow rate is larger/lower than the limitation by allowable deviation.
4. ID fan instruction is maximum/minimum.
5. Feed water flow is lower/higher than setting value by allowable deviation.
6. Feed water instruction is maximum.
7. Steam turbine control valve is at the maximum/minimum position.
8. ULD is larger than the actual power / actual power is higher than the ULD by allowable deviation.
9. Throttle pressure is lower/higher than setting value by allowable deviation.
10. Fuel rate is lower/higher than setting value by allowable deviation.
11. Air flow rate is lower than setting value by allowable deviation.
12. Furnace pressure is lower than setting value by allowable deviation.
13. Furnace pressure is higher than setting value by allowable deviation.
14. ULD is limited by upper/lower limitation.
Boiler main control
1. Boiler instruction under CCS mode
     Boiler main control receives ULD and throttle pressure signal. Under CCS, unit power deviation and pressure deviation
signal amended by ULD will be sent to boiler main control together, for PI operation. The actual ULD will be sent into
boiler main control as the feed forward signal to form the boiler main control instruction.
2. Boiler instruction under BF mode
     When the boiler main control is in auto mode and steam turbine main control is in manual mode, the pressure deviation
signal amended by ULD will be sent to boiler main control, for PI operation. The main steam flow rate signal will be sent
into boiler main control as the feed forward signal to form the boiler main control instruction.
3. Boiler instruction under BASE mode
     In the BASE mode, boiler main control is in the manual mode, operator can change the main instruction through station
“S”.
  

Boiler main control will switch to manual mode when

Two FD fans are in manual mode
Fuel rate main control is in manual mode
Fault in main steam pressure signal
Fault in main steam flow rate signal

Turbine main control

Turbine main control receives actual ULD and throttle pressure signal.
1. Steam turbine instruction under CCS mode
      Under CCS, unit power deviation and pressure deviation signal amended by ULD will be sent to steam turbine control
together, for PI operation. The actual ULD will be sent into steam turbine main control as the feed forward signal to form
the steam turbine main control instruction.
2. Steam turbine instruction under TF mode
     When the boiler main control is in manual mode and the steam turbine main control is in automatic mode and the main
control is controlling the throttle pressure, the pressure deviation signal amended by ULD will be sent to steam turbine
main control, for PI operation. The boiler instruction amended by pressure will be sent into steam turbine main control as
the feed forward signal to form the steam turbine main control instruction.
3. Steam turbine instruction under BASE mode
When the boiler main control is in automatic mode and the steam turbine main control is in manual mode, operator can set
the steam turbine valve position instruction through “N” station.

    Steam turbine main control will switch to manual mode when

  1. Steam turbine trips.
  2. DEH exits from remote mode.
  3. Fault in main steam pressure signal.
  4. Main steam pressure deviation exceed limitation.
  5. Valve position instruction deviation exceed limitation.