WHAT IS A CONTROL SYSTEM ?

• A SYSTEM WHICH AUTOMATICALLY

TAKES CORRECTIVE ACTION TO
ELIMINATE ANY ERROR IN THE
PROCESS AND KEEPS THE DESIRED
OUTPUT WITHIN PERMISSIBLE LIMITS.

• A CONTROL SYSTEM CAN BE AN OPEN

LOOP OR CLOSED LOOP, DEPENDING
UPON THE ERROR DETECTION
MECHANISM.
 TYPES OF CONTROL SYSTEM
• AN AUTOMATIC CONTROL SYSTEM IS
USED TO MAINTAIN ITS OUTPUT
WITHIN DESIRABLE LIMITS BY MEANS
OF A CONTROL ACTION.THE ERROR
SIGNAL IS USED TO ACTUATE CONTROL
ACTION THROUGH CONTROLLER.
THESE CONTROL ACTIONS ARE :
• PROPORTIONAL
• DERIVATIVE
• INTEGRAL
• COMBINATON OF ABOVE
CONTROL LOOPS IN SERVICE AT UNCHAHAR

• PI CONTROLLER:-
1.DRUM LEVEL
2.FUEL MASTER
3.AIR MASTER
4.MILL AIR FLOW
5.PA HEADER PRESSURE
6.FEEDER SPEED OR COAL FLOW
• PI-PI CONTROLLER
1.FURNACE DRAFT
2.FRS DP
3.SH/RH CONTROL
• PID CONTROLLER:-
1.MILL O/L TEMP. CONTROL
2.COMBUSTION CONTROL
COMBUSTION CONTROL

THE OBJECTIVE OF ANY CONTROL

SYSTEM IS TO MONITOR AND
CONTROL VARIOUS PARAMETERS
AND INTER LINKED SYSTEMS WITHIN
THE DESIRED LIMITS.IT WOULD
OTHERWISE BE VERY DIFFICULT OR
VIRTUALLY IMPOSSIBLE TO MONITOR
& CONTROL SO MANY DIFFERENT
PARAMETERS AND SYSTEMS
SIMULTANEUOSLY.
COMBUSTION CONTROL

IT IS A CONTROL LOOP SYSTEM WHICH

CONTROLS AND CREATES AN
ENVIRONMENT INSIDE FURNACE TO
ENSURE CORRECT AMOUNT OF AIR
WITH RESPECT TO THE ADMITED COAL
SO AS TO COMPLETELY BURN
ALL THE FUEL.
INSUFFICIENT AIR RESULTS IN UNBURNT
FUEL WHILE EXCESS AIR INCREASES
THE QUANTITY OF WASTE HEAT.
ADVANTAGE
WITH A SINGLE COMMAND i.e.VARIATION OF
THROTTLE PRESSURE FROM TURBINE DESK ONE
CAN CONTROL TOTAL AIR FLOW IN THE
FURNACE ,TOTAL FUEL IN THE FURNACE AND
THEIR COORDINATED CONTROL TO MAINTAIN
AIR FUEL MIXTURE AND THROTTLE PRESSURE.

DISADVANTAGE
RATIO OF FUEL TO AIR / FEEDER SPEED IS IN
ITSELF VARIABLE AND DEPENDS ON MANY
FACTORS SUCH AS EFFICIENCY OF MILL
CONTROL SCHEME ,PERCENTAGE OF ASH IN
FUEL AND EFFIENCY OF THE MILL CONTROL
SYSTEM.
COMPONENTS OF COMBUSTION CONTROL

THIS LOOP CONTAINS TWO MAJOR SECONDARY

LOOPS:

AIR MASTER AND FUEL MASTER

MASTER CONTROL OF THESE TWO

CONTROLLERS IS COMBUSTION CONTROL.
 MASTER PRESSURE CONTROLLER
THROTTLE THROTTLE PR.
PRESSURE SP ACTUAL

PID
CONTROLLER

MIN 75 % ACTUAL
ACTUAL TOTAL AIR
TOTAL FUEL
MAX 40 %

F(X)
MAX MIN BTU

A B
TO AIR MASTER TO FUEL MASTER
AIR FLOW MASTER

FROM MASTER
CONTROLLER
A

O2 TRIM F(x)
70 % TO 110%
ACTUAL
AIR FLOW
PI

TO FD FAN VANES
FUEL MASTER

FROM MASTER ACTUAL FUEL

CONTROL FLOW
B

PI

TO RC FEEDERS
 BTU CURVE

RELATION
180
BETWEEN
BTU AND
FUEL/ AIR
RATIO
140
0 % = 0.5
50 % = 0.7
100 % = 0.9
WOLF L A OC

100
0 50 100
BTU IN %

TOTAL AIR AT 800 T/HR

CCS- CO-ORDINATE CONTROLS

AN INTEGRATED APPROACH TO CONTROL

FINAL OUTPUT OF THE TURBO-GENERATOR
i.e. LOAD, KEEPING ALL OTHER IMPORTANT
PARAMETERS LIKE THROTTLE PRESSURE ,
TOTAL FUEL FLOW , TOTAL AIR FLOW i.e.
COMBUSTION INSIDE FURNACE ,OXYGEN
AND FURNACE PRESSURE WITHIN LIMITS.
CCS- CO-ORDINATE CONTROLS

THE OBJECTIVE OF THIS CONTROL SYSTEM IS TO

OPERATE THE TURBINE ,GENERATOR AND BOILER
AS AN INTEGRATED UNIT.BY THE COORDINATED
ACTON IS MINIMUN INTERACTION BETWEEN
CONTROL VARIABLES OF UNIT GENERATION ,
STEAM PRESSURE ,FLUE GAS OXYGEN,FURNACE
DRAFT AND STEAM TEMPERATURE BY
APPROPRIATE SIMULTANEOUS OPERATION .
MANIPULATED VARIABLES OF FUEL,FEEDWATER ,
AIR AND TURBINE GOVERNER
THE CCS PROVIDES FOUR DIFFERENT OPERATING
MODES
CCS

CCS IS DESIGNED FOR FOUR DIFFFERENT

MODE OF OPERATIONS DEPENDING UPON THE
STATUS OF THE TWO MAIN UNITS i.e.
TURBINE AND BOILER.
AT ANY ONE POINT OF TIME ONLY ONE MODE
CAN BE SELECTED.

TURBINE BOILER
MANUAL MODE MANUAL MANUAL
TURBINE FOLLOW MODE AUTO(REMOTE) MANUAL
BOILER FOLLOW MODE MANUAL AUTO
CO-ORDINATE MODE AUTO(REMOTE) AUTO
CCS
MODE SELECTION LOGIC:

CO-ORDINATE MODE
PR. CONTROL BY BOILER
MW CONTROL BY TURBINE BASED ON SP FROM CMC
.
BOILER FOLLOW MODE
PR. CONTROL BY BOILER
MW CONTROL BY TURBINE BASED ON LOCAL SP(EHTC)

TURBINE FOLLOW MODE

PR. CONTROL BY TURBINE
MW CONTROL BY BOILER

MANUAL MODE
MW CONTROL BY TURBINE
PR. CONTROL BY BOILER
CCS
COORDINATE MASTER CONTROL:
IN THIS MODE OF OPERATION BOTH TURBINE AND BOILER
REMAINS IN AUTO . M W IS CONTROLLED BY EHTC AND THE
STEAM PRESSURE i.e. MS THROTTLE PRESSURE IS
CONTROLLED BY BOILER FIRING RATE CONTROL.
THE SET POINT FOR EHTC IS GENERATED FROM CMC
CONSOLE.

BOILER FOLLOW MODE:

IN THIS MODE OF OPERATION TURBINE REMAINS IN LOCAL
i.e. LOAD IS CONTROLLED BY EHTC SET POINT FROM
TURBINE CONSOLE.WHEREAS BOILER FUNCTIONS TO
MAINTAIN THE THROTTLE PRESSURE.EHTC LOAD SET POINT
IS USED FOR FEEDFORWARD TO BOILER MASTER.

BOTH CMC AND BFM HAVE THE ADVANTAGE OF QUICK

RESPONSE TO LOAD CHANGES AND BETTER CONTROL
CCS
TURBINE FOLLOW MODE:
IN THIS MODE OF COTROL STEAM PRESSURE IS
CONTROLLED BY TURBINE AND LOAD IS CONTROLLED
BY BOILER
TFM WILL AUTOMATICALLY SELECTED WHEN RUNBACK
OCCURS AND SYSTEM IS NOT IN MANUAL MODE.

BOILER MASTER :

THIS CONTROLLER CONTROLS COMBUSTION IN THE

FURNACE AND MAINTAINS THROTTLE PRESSURE BY
VARYING FIRING RATE. SLIDING PRESSURE MODE
CHECKES BOILER LOAD INDEX FOR THE CALCULATION
OF THROTTLE PRESSURE SET POINT.
 MANUAL MODE SELECTION

MANUAL MODE
SELECTED
THROTTLE AIR MASTER AND FUEL
PRESS TX OK MASTER AUTO.
AND
TURBINE IN LOCAL

OR OR 2

3
1 4
S R

MA

MANUAL MODE
 TFM MODE SELECTION

TFM CMC BFM

AND PR DEV >< +-1.5%

RELEASE

TUR.IN LOCAL AIR MASTER AND FUEL

MASTER AUTO.
AND

THROTTLE
PRESS TX OK AND
RUNBACK IN ACTION

OR OR 1
3
2 4
S R

TF

TFM
BFM MODE SELECTION
CMC

TFM BFM

AND EHC LOAD >< +-2.4%

RELEASE

TUR.IN LOCAL AIR MASTER AND FUEL

MASTER AUTO.
AND

4
OR 1
2
3
S R

BF

BFM
CO-ORDINATE MODE SELECTION

CMC
TFM BFM

AND EHC LOAD >< +-2.4%

RELEASE

TUR.IN LOCAL AIR MASTER AND FUEL

MASTER AUTO.
AND

3
OR 1
2
4
S R

C
O

CMC
 UNIT LOAD SP

CMC BLOCK CMC CONSOLE

DIAGRAM MAX
MINIMUM LOAD SP

MAXIMUM LOAD SP
EHTC LOAD SP
MIN MAXIMUM TURBINE
ACTUAL TURBINE LOAD (FROM TG)
LOAD 2 1
SEL. 2 MANUAL MODE
SELECTOR
SELECTED
ACTUAL TURBINE LOAD 2 1
SEL. 2 SELECTOR 2 1
TFM SELECTOR
SEL. 2
AND OR
RUNBACK IN
ACTION LOAD
INTEGRATOR
BFM
(SWI)
EHTC LOAD SP

2 1 SEL. 2 CMC
SELECTOR SELECTOR SELECTED

IIND ORDER FEEDFORWARD TO

DELAY BOILER MASTER

LOAD SET POINT TO

TURBINE CONTROL EHTC
 CMC BLOCK
DIAGRAM THROTTLE PRESSURE
SP CMC CONSOLE
1
FKG INT 2 SEL. 2 SLPR. MODE
BLI SELECTOR
(SWI) SELECTED

ACTUAL THROTTLE
ADDER PRESSURE
EHTC LOAD SP

1
CMC SEL SEL. 2 FKG MUL
SELECTOR
2
LOAD SP
PID
CONTROLLER

BFM
CMC OR RA

FEEDFORWARD TO ADDER
BOILER MASTER
1
SEL. 2 2
RUNBACK IN ACTION SELECTOR UNIT CAPABILITY

A
AIR MASTER A
DIAGRAM FKG

O2 TRIM
TOTAL FUEL
ACTUAL FKG MAX

INT
BLI
(SWI)

FKG
BLI FKG MAX

O2 TRIM
PIR MAX ADS
MUL RAISE
LOWER

TOTAL AIR FLOW

PIR
ACTUAL

AIR FLOW
SAD 1A/1B MASTER SP
FUEL MASTER
DIAGRAM A

TOTAL SA FLOW
ADDER FKG MIN

TOTAL PA FLOW

PIR
TOTAL FUEL
ACTUAL

MILL BIASING

MAB MCD MEF

END BIASING

PIR

MAIN AIR DAMPER

THROTTLE PRESSURE VARIATION VS
LOAD CHANGE
100% = 250 MW

3..2%
L
O
A
1%
-1..5% -1% 1..5% D

IN
%
-3..2%

THRT. PR.VARIATION IN % (100% =200KG/CM3)

THROTTLE PRESSURE VARIATION VS
LOAD CHANGE

0 – 2.0 KG/CM3 NO VARIATION IN LOAD

2.0 – 2.6 KG/CM3 0-3.675 MW / KG/CM3
2.6 – 3.0 KG/CM3 3.675-6.72 MW / KG/CM3
RUNBACK SYSTEM:

TO MAINTAIN LOAD AS PER THE AVAILABLE CAPACITY OF

THE UNIT AND TO SAVE UNIT FROM TRIPPING RUNBACK
SYSTEM IS INITIATED.EACH AUXILLIARY WHICH IS USED FOR
KEEPING THE RESPECTIVE PARAMETERS WITHIN RANGE HAS
CERTAIN CAPACITY UPTO WHICH IT CAN BEAR LOAD.THIS
LIMIT IN TURN DEFINES THE BOILER LOADING CAPACITY i.e.
HOW MUCH LOAD CAN BE GENERATED WITH THAT
AVAILABILITY.
ALL THESE LIMITS ALONG WITH THE MAXIMUM LOAD i.e. 100%
ARE THEN COMPAIRED BY A MINIMUM BLOCK ,THE OUTPUT OF
WHICH THEN DEFINES THE UNIT CAPABILITY.
 RUNBACK SYSTEM:
THESE LIMITS ARE AS FOLLOWS FOR THE RESPECTIVE AUXILLIARIES:-
1. ID FAN 65% EACH 130 % FOR TWO FANS
2. FD FAN 65% EACH 130 % FOR TWO FANS
3. PA FAN 65% EACH 130 % FOR TWO FANS4.
4. MILL 65% EACH 130 % FOR TWO MILLS
5. TURBINE TRIP/LSR OPER. 60% 100% FOR NORMAL RUNNING
6. BFP 50% EACH 100 % FOR TWO BFPS

ID FAN LIMIT(130 %)

FD FAN LIMIT(130%)

PA FAN LIMIT(130%)
UNIT CAPABILITY

MINIMUN
FUEL LIMIT(130%)

BFP LIMIT(100%) (DELAY 3SEC)

TURBINE / LSR LIMIT(60%)

MAX LOAD (100 %)

 RUNBACK SYSTEM:

FINAL CMC DEMAND i.e. BOILER MASTER DEMAND

CONTINUOUSLY CHECKS UNIT CAPABILITY AND
DEPENDING UPON THE UNIT CAPABILITY THE FINAL
OUTPUT IS GOVERNED.
FOR EX. IF 80 % IS THE NORMAL BOILER O/P DEMAND
AND UNIT CAPABILITY IS 100% AND SUPPOSE ANY AUX.
SAY ID FAN TRIPS THEN BOILER MASTER O/P WILL
BECOME (80 X 65 =52).

BOILER MASTER DMD 1

FINAL BOILER
UNIT CAPABILITY 2 MASTER OUTPUT
SELECTOR
TO AIR AND FUEL
MASTER

RUNBACK IN ACTION SEL 2

 RUNBACK SYSTEM:

RUNBACK SEL

RUNBACK IN SERVICE
AND S
MANUAL MODE

R
RUNBACK IN
MANUAL MODE SEL
ACTION

WHENEVER THESE CONDITIONS FULFILL “RUNBACK IN

ACTION” ALARM WILL APPEAR AND TURBINE CONTROL
WILL TRANSFER INTO PRESSURE CONTROLLERFROM
LOAD CONTROLLER AND TFM OF CMC WILL ACTIVATE.