UNCHAHAR

CMC IMPLEMENTATION IN OBSOLETE

ISKAMATIC TG CONTROL SYSTEM

NTPC UNCHAHAR

• Parsuram Saha, DGM(C&I)

• Neeraj Agarwal, Sr. Supdt.(C&I)
• A.K.Goel, Sr. Supdt. (C&I)
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 • SECURING FUEL SUPPLIES
FUEL • SOARING FUEL PRICES
• COAL QUALITY

• TECHNOLOGICAL OBSOLESCENCE
AGING FLEET • PERFORMANCE DETERIORATION
• LIFE EXTENSION

ENVIRONMENTAL • ASH DISPOSAL

ISSUES • CO2 EMMISSION

• FINANCIAL HEALTH OF DISCOMs/SEBs

COMMERCIAL
• HIGH T&D LOSSES
ASPECTS
• REDUCTION IN GENERATION COST 3
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 R&M In-house Innovations

• Phased process • Bridging the

technological gap
• Huge Financial between old & new
Implication
system
• Significant
• Safety features
implementation time
adopted for Inter-
• May require long unit panel signal
shutdowns exchange
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 2010 – CMC Implemented

2008-09 - R&M of BOP carried out

1998-99 - BFM Implemented

1992 - Takeover by NTPC.

BFM by design but not commissioned

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 Th. Pr.
Load

Air

Fuel

8
Load

Th. Pr.

Air
Fuel

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Coordinated system response during

rapid load variations, thus ensuring grid

stability and maintaining critical unit

parameters within safe limits.

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CMC IMPLEMENTATION

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 DDCMIS
(CMC Logic)

TG
TG Desk Control
(emergency) Panel
(hardware)

CMC
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 Unit Load
Set Point

Fuel & Air

+ d/dt Time Delay
Control
Throttle Pressure Unit Load
Set Point Controller

PC LC
Throttle Pressure
Controller

MW
Throttle
Generated
LT
Pressure PT

Boiler Turbine Generator

Turbine Governor
Valve 13
Non-availability of Iskamatic cards due to obsolescence

System safety involved with inter-panel signal exchange

Spacing in TG Panel for new card & terminations

Reliable coal flow measurement in volumetric Feeders

Poor Boiler response

Control Loop response time of Drum level control,

furnace draft control, air flow control, etc 14
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 Identification of hardware changes
 Identification of inter-panel signal exchange
 Ensuring cards availability & other hardware
 Testing of the cards healthiness.
 Designing of TG Iskamatic Panel internal wiring changes.
 Designing, Implementation & validation of CMC logic in DCS.
 Identification of additional monitoring signals in DDCMIS
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• Spare channels & blocks of the existing cards were used
• Some of the cards were arranged from other power plants
• Repaired some of the old cards.

 Current to Voltage convertor (AIU-12) - 02 no.

 Voltage to Current convertor (AUI-12) - 01 no.
 MAX / UMS selector (AVB-11) - 02 nos.
 NOT Gate (FA-15) - 01 no.
 OR Gate (VA-11) - 02 nos.
 Set Reset (VS-11) - 01 no.
 Relay - 02 nos.
 Signal isolator - 04 nos.
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 ANALOG INPUTS DIGITAL INPUTS

 CMC Load Set Point  CMC ON Status

 CMC Min. Load Set Point  CMC OFF Status

 Throttle Pressure Actual  Turbine Follow Mode Selected

 Throttle Pressure Set Point  Run Back In Action

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 ANALOG INPUTS DIGITAL INPUTS

 Actual Load  CMC ON From ATRS To DCS

 Generator Frequency  IP Mode Selected

 EHTC Load Set Point  LP Mode Selected

 EHTC Load Reference  Pressure Controller Active

 TSE Upper Load Margin  Pressure Controller ON

 TSE Lower Load Margin  EHTC Fault

 TSE Fault

 Turbine Tripped

 Frequency Influence ON

 LSR operated
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COMMUNICATION FAILURE
IS UNFORESEEN
BUT
CATASTROPHIC

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Three tier protection implemented for taking
care of Load set point signal failure between
DCS & TG controls

CMC LOAD SET PT

CMC MIN. LOAD SP MAX EHTC LOAD CONTROLLER

EHTC PANEL INTERNAL

FIXED LOAD SP
(6.00 V =150 MW)

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CMC will be automatically switched OFF in case of :

 Any selected transmitter failure

 Communication failure

 Signal isolator failure

 EHTC card failure.

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A separate on/off push button provided at
turbine desk, directly hardwired to ATRS panel,
for making CMC ON/OFF in case of

 any communication failure,

 any hardware failure.

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CMC mode can be selected from OWS if :

 Air master is in Auto

 Fuel master is in Auto

 Drum Level is in Auto

 Boiler Master is in Auto

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 DCS
CMC ON (OWS)

BLR MSTR ON AUTO A

N
LP MODE SELECTED D

NO EHTC FAULT

LOAD DEVN. < 2 %

(CMC SP ~ EHTC SP)
S CMC ON
S-R (DCS)
PR CNTLR IN ACTION R

IP MODE SELECTED CMC OFF

NOT
(DCS)
TFM SELECTED
O
BFM SELECTED R

MAN MODE SELECTED

RUN BACK IN ACTION

TURBINE TRIP

BOTH HPBP OPEN > 2%

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 DCS /UCD ATRS
CMC ON PB
(TG DESK)

CMC ON
A
(DCS)
N
LOAD CNTLR
D
IN ACTION
NO EHTC
S CMC ON
CMC OFF PB FAULT
S-R (TG)
(TG DESK) R

CMC OFF
(DCS)
LOAD CNTLR
NOT IN ACTION O
R
EHTC FAULT
IP MODE
SELECTED CMC FAULT
(TG DESK)

O
TFM SELECTED R
(OWS) O
R IP MODE
RUN BACK SELECTED
IN ACTION
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 DCS /UCD ATRS

RL
ACTUAL LOAD
(0-250 MW) 2 SEL 2 A
UMS F
Z
1
A
LOAD SP R S 12
RAISE/LOWER B
(TG DESK) L
12

CMC LOAD SP 4-20 mA I/V 2-10 V

ISO-1 M
(DCS) CONV
A 1
X LOAD
I/V 2-10 V 2 UMS REFERENCE
CMC MIN ISO-2 4-20 mA
CONV S SEL 2 PR
LOAD SP
E
(DCS) 6.00 V L
150 MW
TG MIN. LOAD SP
CMC ON (TG)

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 Load Set Point Generation – TSE Upper Load margins, TSE Lower
Load margins, Unit capability & Load gradient governs the final CMC
load set point to Turbine EHTC Controls.

 Load SP Tracking – CMC and TG desk EHTC load set point tracks
actual Load for smooth change-over when CMC is made ON/ OFF.

 Runback scheme – If any ID, FD, PA, BFP or Mill trips, then machine
will switch over to Turbine Follow mode and IP mode will be selected.

 Pressure & Frequency Infl. correction – Load set point to TG is

slightly corrected to counter the changes in Throttle Pressure &
frequency, thus ensuring stability. 30
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Feeder speed pick-up relocated on sprocket of drag chain so
that feeder speed becomes zero in case of drag chain breaks.

CHAIN
BREAKS

Thus coal flow measurement, a vital parameter in CMC loop,

was made more reliable. 34
ID/FD/PA fan IGV & Blade Pitch Control pneumatic actuators
were replaced by motorised actuators

 Old pnematic actuators had poor reliabilty & sluggish

response resulting in poor control loop response time.
 The new motorised actuators were faster & maintenance
free.
 This improved the response time
of air flow, PA hdr. & furnace draft
control loop.

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The signal transducers used for TSE Lower & Upper margins
signals from TSE panel to DCS were :
 Non linear
 Poor accuracy
 Unreliable due to frequent breakdowns

100 ohm Resistor

+
0-100 mV
0-1 mA 4-20 mA 0-1 mA
(To DCS mV
(TSE) (DCS) (TSE)
I/P card)
_

Overall accuracy : 5 % Overall accuracy : 0.5 %

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 Adaptive Proportional Gain, slow Integration
action, Small derivative action
 Feed Forwards :
Load SP change

Target Steam Flow

Throttle Pressure Set Point Change

Frequency Influence Correction

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 -/+3% RAMP FOR 5 MIN
LOAD

Th. Pr.

Air
Oxygen

Fuel

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LOAD -/+5% RAMP FOR 5 MIN

Th. Pr.

Air

Fuel

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 LOAD -/+10% RAMP FOR 2 MIN

Th. Pr.

Air

Fuel

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 Throttle Furnace SH Steam RH Steam
Load/ Rate of Flue gas O2 Drum Level
Pressure Pressure Temperature Temperature
Change (% of Deviation Deviation
Deviation Deviation Deviation Deviation
MCR per min) (%) (mmWC)
(Kg/cm2) (mmWC) (deg.C) (deg.C)

Steady State +/- 2 +/- 0.4 +/- 3 +/- 3 +/- 5 +/- 15

+/-3% for 5 min. +/- 3 +/- 0.6 +/- 10 +/- 6 +/- 6 +/- 18

+/-5% for 5 min. +/- 3.5 +/- 0.8 +/- 10 +/- 6 +/- 8 +/- 30

+/-10% for 2 min. +/- 4.0 +/- 1.0 +/- 13 +/- 6 +/- 15 +/- 50

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21
20
DEVIATION

15 12 12 11 BFM
10 CMC
6 6
5
3
5

0
THR. PR. SH TEMP. RH TEMP. HEAT RATE
(Ksc) (Deg.C) (Deg.C) (Kcal.)

* Data analysis for Load change of 3%/min. for 5 mins.

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Coordinated system response resulted in :

 Safe Plant operation

 Improved system stability

 Enhanced operation flexibility

 No temperature excursions during Mill
changeover or load variations

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 Increased unit Efficiency

 Reduced generation cost

 Minimisation of UI losses
 Better Control of critical unit parameters
 No thermal stresses on turbine due to reduced
cyclic variations

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 In today’s scenario of fast changing technological
advancements the systems are grappling with problem of
obsolescence.

 With innovative approach adopted for In-house modifications,

we can overcome this challenge and that too without being
dependent on OEM for modifying the existing system.

 This successful implementation of CMC has demonstrated that

with the in-house expertise & resources, systems can be
upgraded in sync with the modern technologies to further
strengthen the system requirements. 46
Innovation always beats the limitations by
well planned team perseverance. It is a job
that has no defined end point and there is
always scope for further performance
enhancement.

The journey continues…..

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