Proposed plan for field trials of Generic MPC for SH Steam

Temperature Control at NTPL 2 x 500 MW TPP site,Tuticorin

BHEL has recently developed an advanced controller which will regulate the De-Super
Heater (DESH) spray in order to control the Super Heater (SH) steam temperature
based on model predictive control (MPC) philosophy. The same was rigorously tested
on a Thermal Power Plant Simulator at BHEL R&D. It is now proposed to test the MPC
at NTPL 2 x 500 MW Tuticorin site. Following is a brief description of the control
philosophy and the proposed action plan for field trials.

Brief description of MPC:

Model Predictive Controller (MPC) is an advanced control scheme comprising of two

parts:

 The predictor - The predictor models the process to be controlled online and 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. Optimisation logic is used to ensure satisfactory control.

MPC will use the current and past values of all related parameters such as spray valve
position, SH steam temperature, fuel flow rate, air flow rate, main steam mass flow rate,
main steam pressure, load etc., to predict the model and generate control action.

Action Plan:

1. The MPC software will be loaded in a laptop / workstation and the same will be
brought to the site. It will be interfaced to the MaxDNA network available in the
control room. (Action: R&D)
2. An IP address should be provided for the above networking. ( Action: site / EDN /
R&D).
3. The data exchange between MaxDNA system and MPC will be via OPC. (Action:
R&D)
4. Signals of spare channels have to be allotted for output signals generated by
MPC (Action: Site / EDN /R&D).
5. Both input/output signals for MPC will have to be configured in MaxOPC server
and MaxHistorian. List of required signals are given in Annexure 1 below.
(Action: Site / EDN / R&D).
6. Load or fuel flow change (equivalent to 10 - 20 MW) will be have to be injected
for the purpose of training the Predictor. (Action: Site / EDN / R&D)
7. In the first phase of field trials the performance of the Predictor will be evaluated.
Only after satisfactory performance of the predictor, next phase of field trials,
described below, will be undertaken.
8. In the second phase of field trials, the PID controller output to the DESH spray
will be substituted by the output of the MPC Controller and the performance of
the MPC evaluated. Bump-less transfer from PID to MPC is incorporated.
9. Logic has to be suitably modified in relevant MaxDNA DPU to switch between
PID and MPC. (Action: Site / EDN / R&D)
 ANNEXURE 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 (Right) If feedback is not available
command valve is also
acceptable
6 Fuel flow
7 Total Air flow
8 Main Steam pressure
9 Main Steam flow
10 PID status To know whether SH
temperature control loop is
in PID mode or not
(2) Outputs generated by MPC
1 Spray control valve position command (Left) In the first phase this signal
will not be connected to
actual command sent to
Spray control valve.
Spare tag to be allotted for
this signal.
2 Spray control valve position command (Right) In the first phase this signal
will not be connected to
actual command sent to
Spray control valve.
Spare tag to be allotted for
this signal.
3 Predicted SH outlet temperature (Left) Spare tag to be allotted for
this signal.
To check accuracy of
predictor
4 Predicted SH outlet temperature (Right) Spare tag to be allotted for
this signal.
To check accuracy of
predictor