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Write-up on CLCS – COORDINATED MASTER CONTROL

References:

CLCS Document No.4330-405-PVI-P-016

I & C Device List

Basic symbols for Control and Instrumentation

Abbreviation

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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Write-up on CLCS – COORDINATED MASTER CONTROL

1.0 OVERVIEW
The purpose of this document is to explain and describe the implementation of Coordinated Master Control
and Boiler Master Control used in this project.

2.0 COORDINATED MASTER CONTROL

PURPOSE:
The purpose of this controller is to provide Load Set Point to Boiler Master and Turbine Master as
per Unit Master Output when they are in Coordinated mode; while taking into account the
Temperature Margins of Turbine and the margins of Fuel Master/Air Master/Feedwater
Controllers. The controller also calculates the Unit Capability based on the availability of
auxiliaries of the unit and ramps down the Load Set Point at a pre-set rate when one of the
auxiliary trips. The various auxiliaries whose status is being monitored are as follows:
 ID Fan
 FD Fan
 PA Fan
 Primary/Secondary Air Pre Heaters
 BCW Pump
 Turbine
 CEP Pump
 CW Pump
 Mills
FUNCTIONAL DESCRIPTION:
Automation System Structure:
The Automation of Coordinated Master Controller allows the Operator to set the Load Set Point
from the MMI unit (OWS/LVS etc) of the DDCMIS or through Hand Manual Station located in
the Central Control Room (CCR). It consists of Commands, Interlocks and Monitoring functions
necessary to manage the system correctly. The operator can set the controllers in Cas/Man mode
and vary the Unit Load SP.
OWS/LVS Operator Interface:
The following operator interfaces based on OWS/LVS operations are available in CCR.
 To Set Unit Load SP.
 Cas/Man Selection of controller.
UCP Mounted Operator Interfaces/Devices:
 Hand Auto/Manual station for Unit Master 3-CF-HK-8201.
CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4
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 Window Annunciators (based on customer inputs)

Control Philosophy
Unit Master Set Point comes from Load Dispatch Centre. The output of Unit Master Auto Manual
Station is fed to a Ramp Generator. The Ramp Generator’s output Rate of Change limit is set after
detecting the direction of change while checking the Boiler margins. If Boiler margin (i.e.,
Fuel/Air/Feedwater Controllers deviations are within limit in the intended direction of change) the
Ramp Generator’s output is allowed to change at a preset rate.
A correction is applied to the set point according to deviation of frequency through a summer. The
output of the summer block is passed further on to a Ramp Generator through a Switch if CMC
mode is selected. If Boiler Follow mode is selected the input to the second Ramp Generator is the
Delayed Load Set Point of Turbine Controller. If the Boiler is in Manual mode, Actual Load is fed
as the input to the second Ramp Generator. The above said switching function is achieved using a
Switch Block. The second Ramp Generator output is ramped according to the Output rate of
Change limit. The output rate of change limit is calculated according to the direction of change.
The output is allowed to change according to a rate of change if direction blocking is not present
in the desired direction of change. Change in any direction is allowed only if the deviation of the
following controllers are within a predetermined limit. The controllers whose deviation is
monitored when an increase in SP is desired are:
 Feed Water flow Control
 Air Flow Control
 Fuel Flow Control
 PA Header Pressure Control
The controllers whose deviation is monitored when a decrease in SP is desired are:
 Feed Water flow Control
 Air Flow Control
 Fuel Flow Control
The rate of change of limit is the minimum of the following:
 Load Rate of Change limit set by the operator
 The rate of change limit calculated by the Turbine Stress Evaluator(TSE) according to the
margin available in the direction of change desired if TSE influence is turned on. Otherwise a
safety margin of 50% is considered. The direction of change is determined by comparing the
difference between the input and output of the ramp generator with a direction specific
numeric with a value of +1 or –1(adjustable). When the difference cross the limit the
direction of change is sensed and the corresponding margin is selected.
The upper limit of the Second Ramp Generator is the minimum of the following:
 Unit capability
 Max Load SP set by the operator.

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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Write-up on CLCS – COORDINATED MASTER CONTROL

 Max Load permissible by TSE.

Unit capability is calculated according to the auxiliary equipment availability. All the auxiliary
equipments mentioned in the beginning of this section are monitored continuously and unit
capability due to the individual equipments are compared with the Load SP and the minimum is
selected as the SP to the Unit Capability ramp generator. When any one of the equipment trips the
SP to the Unit capability ramp generator comes down correspondingly. The output of the Ramp
Generator is brought down by Runback action. The runback rate depends upon the equipment that
tripped.
Maximum load permissible by TSE is calculated by adding the Upper margin provided by TSE
with Actual Load.
The lower limit of the second Ramp Generator is the maximum of the following:
 Minimum Load SP set by the operator
 Minimum Load Permissible by TSE.
Minimum Load permissible by TSE is calculated by subtracting the Lower margin provided by
TSE from Actual Load.
The output of the second Load Ramp Generator is passed on to the Turbine Load controller as
Load setpoint after delaying the output (by using a second order delay element)and subtracting a
value (bias due to Throttle pressure deviation when CMC mode is selected).
The same output is fed as Feed Forward signal to Boiler Master after adding a bias due to
Frequency Correction (if the Frequency influence is kept ON in EHTC) when the Boiler Master is
in CMC mode.

Unit Load SP Generation control: (Refer dwg. 3CJY00_01,02,03,04)

As explained above the controller calculates the Unit Load SP for Boiler/ Turbine.
Functional Blocks used:
CJY00_1C21: Unit Master Auto/Manual Station.
CJY00_1C22:REGCALC BLOCK
CJY00_1C23: SUMMER Block for adding Frequency influence.
CJY00_1C24: SWITCH Block to switch between Load SP of Unit Master/Load
Reference (PRTD)/Actual Load according to the mode selected.
CJY00_1P06: CALCULATOR Block to calculate the difference between the output and
input of the ramp generator.
CJY00_1N56, CJY00_1N57: NUMERIC Blocks used to detect the direction of change.
CJY00_1N51: NUMERIC Block to pass on Frequency deviation signal when the same is
not bad.
CJY00_1P01, CJY00_1P02, CJY00_1P03: GENLIN Block used to calculate the
correction factor due to frequency deviation.

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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Write-up on CLCS – COORDINATED MASTER CONTROL

CJY00_2C21: RATIO Block used as ramp generator to limit the output rate of change
according to the TSE margin available. The Output High/Low limits are determined
according to Unit capability , TSE margin and the Maximum/minimum limit set by the
operator.
CJYOO_2P01: LEADLAG Block to provide a second order delay to Unit Load SP
generated.
CJY00_2N58: NUMERIC Block used to determine throttle pressure deviation. The
deviation of the Boiler master controller is selected and passed on according to the mode
(CMC/Boiler Follow) mode selected.
CJY00_2P02: GENLIN Block used to determine the influence of Throttle Pressure
deviation on generated Unit Load SP.
CJY00_2N51: NUMERIC Block used to pass the bias due to Throttle pressure deviation
when CMC mode is selected.
4CJY00_2C22: SUMMER Block for calculating the Load SP to EHTC after taking into
account the bias due to Throttle pressure deviation.
CJY00_02.CALCULATOR: CALC Block used to determine the Feed forward signal to
Boiler master after taking into account the frequency correction signal.
CJY00_2N52: NUMERIC Block to pass on Frequency correction signal when
Frequency influence is turned ON in EHTC.
CJY00_3P01, P02, P03, P04, P05, CJY00_4P01, P02: CALC Blocks used to determine
unit capability set point by selecting the minimum capability of the auxiliary devices as
the final setpoint.
CJY00_3N51 TO CJY00_3N73 & CJY00_4N51 TO CJY00_4N57: NUMERIC
Blocks used to determine individual equipment capability according to availability of the
equipment. If the equipment is ON then the capability of the equipment is passed on as
the value of the numeric by the corresponding logic otherwise zero is passed on.
CJY00_4N59 TO CJY00_4N68: NUMERIC Block for determining the individual
auxiliary equipment’s runback rate. The rate is kept as zero until the equipment’s
capability is more than the unit SP. Once the equipment’s capability comes below unit SP
a predetermined runback rate is passed on.
3CJY00_04.RUNBACK: HILOAVG Block used as high selector to select the highest of the
available run back rates.
 CJY00_3C21: RATIO Block used as ramp generator for determining unit
capability. During runback the output is ramped according to the predetermined
rate of the equipment due to which the runback is initiated.
 CJY00_4N69, CJY00_4N70: NUMERIC Blocks used by the operator to set
Maximum/ Minimum Load SP.

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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Write-up on CLCS – COORDINATED MASTER CONTROL

CJY00_4P05: CALC Block used to calculate the upper and lower limit of Unit SP ramp
generator.
Protection and Interlock:
The unit master is forced to Manual if any one of the following signals is present
 ADS Fault
 RUNBACK is in action
 RUNUP is not permitted
 RUNDOWN is not permitted.
Hand Operated A/M stations for Boiler Master: (Refer dwg. 3CJY00_06)
AutoManual stations located in UCP has the facility to take the controller individually to Manual
mode and manipulate the outputs. This is redundant to the facility available in OWS. This is
achieved using calculator and Logic blocks.
Functional Blocks used:
3CJY00_06.UCP: CALC Block – Increment and decrement command from UCP Auto
Manual stations are taken as inputs and the calculated value is written back to Unit
Master Auto Man Station.

3.0 BOILER MASTER CONTROL

PURPOSE:
The purpose of this controller is to maintain Throttle Pressure of Main Steam at Turbine inlet
around the Set Point. Boiler Master determines the Set Point for Air Master and Fuel Master when
they are in Cas Mode. The Throttle Pressure SP is operator set when the Boiler Master SP is in
Fixed SP mode and is dependent on either Boiler Load Index or Actual Load (Pre Set) when the
SP is in Sliding Pressure Mode.
FUNCTIONAL DESCRIPTION:
Automation System Structure:
The Automation of Boiler Master allows the manipulation of Boiler Demand from the MMI unit
(OWS/LVS etc) of the DDCMIS or through Hand Manual Station located in the Central Control
Room (CCR). It consists of Commands, Interlocks and Monitoring functions necessary to manage
the system correctly. The operator can set the controllers in Auto/Man mode and vary the
recirculation flow.

OWS/LVS Operator Interface:

The following operator interfaces based on OWS/LVS operations are available in CCR.
 Adjusting Boiler Demand.
CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4
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Write-up on CLCS – COORDINATED MASTER CONTROL

 Selection of Transmitters
 Cas/Man Selection of controller.
UCP Mounted Operator Interfaces/Devices:
 Hand Auto/Manual station for Boiler Master 3-CF-HK-8202.
 Window Annunciators (based on customer inputs)
Main Steam Throttle Pressure at Turbine Inlet: (Refer dwg. 3CJY00_01)
Three independent measurements are available. The functional block MIDOF3 calculates the
middle value. The operator has the facility to select between these 4 values (3 transmitters and
Mid value) via GUI.
Functional Blocks used:
3CJY00_01. 3TX_1: HILOAVG block for operator selection.

Control Philosophy
The Set Point is either determined by the operator or depends on Boiler Load Index depending
upon the mode that is selected. If fixed SP mode is selected from MMI the SP is operator
determined. When the same is not selected the SP is determined based upon either Boiler Load
Index or Actual MW. Selection between the two is preset. The Boiler Master can be operated in
two different modes. When the Boiler Follow mode is selected the controller with a Feed Forward
signal based on either Boiler Load Index or EHTC Load Set Point is selected. The selection
between the two-feedforward signals is preset. When Coordinated Mode is selected the controller
with Unit Load SP generated by Coordinated Master as the Feed Forward Signal is selected for
control. When Manual mode is selected or when Run Back in Action the Boiler Master A/M
station trips to Manual mode. When ‘Run Back in Action’ signal is present Turbine Follow mode
Signal is automatically selected and the Unit capability comes down to match the available
capability. This signal is factored (MW to Fuel Ratio) and given as Boiler Master output to the
downstream controller viz., Fuel Master and Air Master signal respectively. This will result in
reduction of Steam Generation to match the available Unit Capacity. The turbine controller
switches to initial pressure mode and starts controlling the Throttle pressure simultaneously. In
order to provide for tracking during manual mode a switch is provided. This switches the Boiler
Master demand to actual Fuel Flow (in terms of Percentage) when Fuel Master controller is not in
Cas mode. With the tracking option ON, the Boiler Master Auto Manual Station Output is made to
track Actual fuel flow (Percentage value) when Fuel Master is in Manual mode. When Fuel Master
switches back to Cas mode a bump is avoided as Boiler Master A/M output was tracking actual
Fuel Flow. Operator can select the various modes of operation (Manual mode, Turbine Follow
mode, Boiler Follow mode and Coordinated Mode) provided the enabling conditions are present
and tripping conditions are not present.

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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Write-up on CLCS – COORDINATED MASTER CONTROL

Boiler Master Control: (Refer dwg. 3LCY02_02)

Functional Blocks used:
CJY00_2C28: RATIO Block for operator set Throttle Pressure Set Point.
CJY00_2C29: SWITCH block for switching between Fixed SP mode and sliding
pressure mode.
3CJY00_2C23.PIDA, 3CJY00_2C24.PIDA: PIDFF Blocks, which control the Throttle
Pressure, according to SP during Coordinated Mode and Boiler Follow Mode
respectively.
CJY00_2N56: NUMERIC Block to select BLI/EHTC setpoint as Feed Forward signal
for Boiler Master when the Boiler Follow mode is selected.
CJY00_2C25: SWITCH Block to switch between the two controllers during Boiler
Follow mode and Coordinated mode respectively.
CJY00_2C26: AUTOMAN Block that acts as Boiler Master Auto Man station.
CJY00_2C27: SWITCH Block to switch between Boiler Master Output and Fuel Flow.
CJY00_5D41, D42, D43, D44: DIGCOMP Blocks to select Manual Mode, Turbine
Follow Mode, Boiler Follow Mode and Coordinated Mode respectively.
CJY00_2N56: NUMERIC Block for determining the bias to be added to Operator set
Throttle Pressure Set Point to calculate HPBP Set Point.
3CJY00_02.CALCALCULATOR_1: SUMMER Block for calculating the HP Bypass
Set Point.
Hand Operated A/M stations for Boiler Master: (Refer dwg. 3CJY00_06)
AutoManual stations located in UCP has the facility to take the controller individually to Manual
mode and manipulate the outputs. This is redundant to the facility available in OWS. This is
achieved using calculator and Logic blocks.
Functional Blocks used:
3CJY00_06.UCP: CALC Block – Increment and decrement command from UCP Auto
Manual stations are taken as inputs and the calculated value is written back to Boiler
Master Auto Man Station.
Protection and Interlock:
The Boiler Master Auto Man Station is tripped to Man when any of the
 Transmitters’ deviation high or all three transmitters signal bad.
 Man Mode is selected from MMI.
 Run Back in Action.
 Turbine follow Mode is selected.

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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The Auto Man Station is forced to CAS mode when Boiler Follow mode selection condition is
present.
The output of Auto/Man Station is forced to a value proportionate to Unit Capability when
Runback is in Action.

Legend for Control Schemes:

AI - Analog Input
AO - Analog Output
DI - Digital Input LB - Logic Block
DO - Digital Output NM - Numeric
NN - Node Number FL - Flag
MM - Module Number
SS - Slot Number

Abbreviation List:
MID OF 3 -Median value selection
HILOAVG -Selection of average or Operator select
PID -Proportional +Integral +Derivative control
RATIO -Ratio control
AUTOMAN -Auto/Manual station
SUMMER -Summing of inputs
GENLIN -Function Generator
SWITCH -Switching between inputs (S1,S2,S3,S4)
CALC -Calculator
OPLOLM -Output Low Limit
OPHILM -Output High Limit
ESWMAN -Switching externally (through logic block) to Manual mode
ESWCAS –Switching externally (through logic block) to Cascade mode
ESWAUTO -Switching externally (through logic block) to Auto mode
ESWENBST -Enabling Mode change
Tag. XXXX -Refers to the internal parameter of the tag
PVFL -Digital Status

CLCS – COORDINATED MASTER DOC. No : D0T195-302-CJY-E00 REV. 4

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