Annexure-1

Write-up on GMPC

Generic Model Predictive Controller (MPC), is an advanced type controller

developed recently by BHEL Corporate R&D primarily for, Super heater (SH)
Temperature Control and Re heater Steam Temperature Control in a Thermal Power
Plant (TPP) using the De-Super Heater (DESH) spray.

Model Predictive Controller (MPC) comprises of two parts:

 The predictor - The predictor models the process to be controlled online in real
time and predicts the outcome of the control action on the process variable
being controlled.
 The Controller - Based on the prediction, the controller will regulate the DESH
spray. Optimization logic is used to ensure satisfactory control.

The model structure is based on process parameters. MPC will use the current and
past values of all related parameters such as spray control valve position, SH steam
temperature, fuel flow rate, air flow rate, Main Steam (MS) mass flow rate, MS
pressure, actual load etc., to predict the model and generate suitable control action.
For real time adaption to process variations, there is a mechanism for dynamic
updation of model. There is a continuous exchange of data between MPC and
conventional Distributed Control System (DCS).

There are two stages of operation for MPC. In the first stage, predictor component of
MPC will collect data from a running plant and create the process model. Once, the
model is ready, the predictor will predict the process parameter namely, steam
temperature. The controller component of MPC will be predicting the command value.
During this stage (i.e. collection of data and subsequent prediction of steam
temperature and control command value), MPC will not interfere with the plant
operation. This is due to fact that, MPC sends PID command value as its own output
and not its predicted control command value.
In the second stage, if MPC is selected from MaxDNA DCS such as by the operator,
MPC sends predicted control command value as its output. In the DCS, MPC
generated value is sent to the spray control valve.
The changeover from PID to MPC is bump less.

During both stages of operation, the changes in dynamics of the process result in
automatic updating of model in MPC. This in turn results in change in prediction values
for temperature as well as control command.

Fail Safe Mechanism:

There is a protective mechanism for change over to existing controller, in case of a

malfunction in MPC. A watch dog signal is used to indicate any failure. If there is a
problem in the communication between MPC & DCS or if there is malfunction in MPC
execution, then a signal is generated and fail safe logic immediately switches to
existing PID controller in a bump less manner.

The following are trend results of previous site trials. The deviation in the predicted
and actual values of SH steam temperature is in range of +/- 3 Deg. C (+/- 0.56%).

Fig.1 SH (Left) temperature prediction error versus actual load at NTPL 2x500 MW TPS, Tuticorin
Fig.2 SH (Right) temperature prediction error versus actual load at NTPL 2x500 MW TPS,
Tuticorin

Fig. 3 SH (Left) temperature prediction error versus actual load at NTPL 2x500 MW TPS,
Tuticorin
Fig.4 SH (Right) temperature prediction error versus actual load at NTPL 2x500 MW TPS,
Tuticorin

Fig.5 SH (Left) temperature prediction error versus actual load at DVC 2x500 MW DSTPS,
Durgapur
Fig.6 SH (Right) temperature prediction error versus actual load at DVC 2x500 MW DSTPS,
Durgapur

Fig.7 SH (Left) temperature prediction error versus actual load at DVC 2x500 MW DSTPS,
Durgapur
Fig.8 SH (Right) temperature prediction error versus actual load at DVC 2x500 MW DSTPS,
Durgapur

Fig. 9: Trend for MPC related parameters for SH Left at DVC 2x500 MW DSTPS, Durgapur
Fig. 10: Trend for MPC related parameters for SH Right at DVC 2x500 MW DSTPS,
Durgapur

The list of signals for operating of MPC are mentioned next in Table 1.
S. No. Description Remarks
(1) Inputs to MPC (required for training of
predictor)
1 SH outlet temperature (Left)
2 SH outlet temperature (Right)
3 Actual load
4 Spray control valve position feedback (Left) If feedback is not available
command valve is also
acceptable
5 Spray control valve position feedback If feedback is not available
(Right) command valve is also
acceptable
6 Fuel flow
7 Total Air flow
8 MS pressure
9 MS flow
10 PID status To know whether SH
temperature control loop is
in PID mode or not. This
status is required as start
 permissive for training of
MPC
(2) Outputs generated by MPC
1 Predicted SH outlet temperature (Left) To check accuracy of
predictor
2 Predicted SH outlet temperature (Right) To check accuracy of
predictor
3 Spray control valve command (Left) MPC command to Spray
control valve.
In the first phase this signal
will not be connected to
actual command sent to
Spray control valve.
4 Spray control valve command (Right) -- do --
5 MPC ready status (Left) This flag is set once MPC
is ready to generate control
value(s)
6 MPC ready status (Right) -- do --
7 Alarm status (Left) This flag is set in case of ay
malfunction in MPC
8 Alarm status (Right) -- do --
9 Healthy status (Left) This is watch dog signal in
form of a square waveform
which indicates the healthy
status of MPC
10 Healthy status (Right) -- do --
11 Spray control valve position predicted Predicted Spray control
command (Left) valve command.
12 Spray control valve position predicted -- do --
command (Right)
Table1 List of MPC related signals