A Multivariable Self-tuning Controller for a D-type Water Tube Industrial Boiler

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The application of a new PID autotuning method for the steam/water loop in large scale ships

In large scale ships, the most used controllers for the steam/water loop are still the proportional-integral-derivative (PID) controllers. However, the tuning rules for the PID parameters are based on empirical knowledge and the performance for the loops is not satisfying. In order to improve the control performance of the steam/water loop, the application of a recently developed PID autotuning method is studied. Firstly, a 'forbidden region' on the Nyquist plane can be obtained based on user-defined performance requirements such as robustness or gain margin and phase margin. Secondly, the dynamic of the system can be obtained with a sine test around the operation point. Finally, the PID controller's parameters can be obtained by locating the frequency response of the controlled system at the edge of the 'forbidden region'. To verify the effectiveness of the new PID autotuning method, comparisons are presented with other PID autotuning methods, as well as the model predictive control. The results show the superiority of the new PID autotuning method

Detailed model for robust feedback design of main steam temperatures in coal fired boilers

Main steam temperatures play a significant role in large coal fired power plant operation. Ideally, main steam temperatures should be accurately controlled to protect the thick wall components against long term overheating and thermal stress while meeting the design conditions at the steam turbine inlet. Although high steam temperatures are beneficial for thermal efficiency, it accelerates creep damage in high temperature components which is detrimental to the life of components. Alternatively, low steam temperatures increase the moisture content at the last stage blades of the turbine, causing the blades to deteriorate and fail. Control of the outlet steam temperature according to design conditions at variable loads is maintained via a balance between heat input (flue gas temperature and mass flow rate), evaporator outlet steam mass flow and spray water. The present control philosophy accuracy of main steam temperatures at an Eskom coal fired power plant was evaluated and compared to the latest technology and control strategies. Improving and optimizing steam temperature controls ensures design efficiency while maintaining long term plant health. The level of spatial discretization applied in simplifying the real boiler for modelling purposes was approached at a relatively high level. The intention was to model normal operating conditions and certain transients such as variable heat input and load changes to see its effect on steam temperatures and to be able to evaluate the performance of different temperature control techniques. The main outcome of this project was to design a robust control system for a dynamic model of the boiler using sets of low order linear models to account for uncertainty. The main concepts, models and theories used in the development of this dissertation include: 1) A detailed thermo-fluid model developed using Flownex to have high fidelity models of the process under varying operating conditions. This model was used to test and evaluate the robust controller design. 2) System Identification in Matlab to construct mathematical models of dynamic systems from measured inputoutput data and identify linear continuous time transfer functions under all operating conditions [1]. 3) Quantitative Feedback Theory (QFT) to design controllers for an attemperator control system at various onload operating conditions. This design was used understand the engineering requirements and seeks to design fixed gain controllers that will give desired performance under all operating conditions. 4) The design of a valve position controller to increase the heat uptake in a convective pass, thereby improving efficiency: Excessive attemperation in the superheater passes is generally associated with high flue gas temperatures which decrease thermal efficiency. Therefore, robust control of the attemperation system leads to an increase in heat uptake between the flue gas and steam in the boiler, resulting in a reduction in the flue gas temperature leaving the boiler, thus improving efficiency. The robust QFT controllers were set up using the valve position control technique and were used to confirm the improvement of control performance. The theories mentioned above were used to understand the control performance under varying plant conditions using a standard cascaded arrangement. It incorporated robust control design and engineering requirements such as bandwidth, plant life, spray water and thermodynamic efficiency. The control effort allocated to each superheaterattemperator subsystem in the convective pass was designed as a multi-loop problem

Distributed model predictive control of steam/water loop in large scale ships

In modern steam power plants, the ever-increasing complexity requires great reliability and flexibility of the control system. Hence, in this paper, the feasibility of a distributed model predictive control (DiMPC) strategy with an extended prediction self-adaptive control (EPSAC) framework is studied, in which the multiple controllers allow each sub-loop to have its own requirement flexibility. Meanwhile, the model predictive control can guarantee a good performance for the system with constraints. The performance is compared against a decentralized model predictive control (DeMPC) and a centralized model predictive control (CMPC). In order to improve the computing speed, a multiple objective model predictive control (MOMPC) is proposed. For the stability of the control system, the convergence of the DiMPC is discussed. Simulation tests are performed on the five different sub-loops of steam/water loop. The results indicate that the DiMPC may achieve similar performance as CMPC while outperforming the DeMPC method

Prediction of PID control model on PLC

PID (Proportional Integral Derivative) is a control algorithm that mostly used in industry. However, users have never known what the PID model that used inside the PLC. By knowing the PID model that used in PLC, users will have more choice in determining the more appropriate tuning algorithm. Also, users can use MATLAB to perform analysis and can implement it to PLC. Through OPC Server (Object Linking and Embedding for Process Control Server) as a software interface, programs on a windows operating system can communicate with industry devices universally. PID model prediction method is done by comparing the output of the plant controlled by PID model in PLC and PID model in SIMULINK MATLAB using OPC Server intermediaries. Based on comparison result in graph and analysis using integral error method, PLC M221 using Parallel PID model and PLC S7-1200 using Ideal PID model

Plantwide Control and Simulation of Sulfur-Iodine Thermochemical Cycle Process for Hydrogen Production

A PWC structure has developed for an industrial scale SITC plant. Based on the performance evaluation, it has been shown that the SITC plant developed via the proposed modified SOC structure can produce satisfactory performance – smooth and reliable operation. The SITC plant is capable of achieving a thermal efficiency of 69%, which is the highest attainable value so far. It is worth noting that the proposed SITC design is viable on the grounds of economic and controllability

Integrated process and control modelling of water recirculation in once-through boilers during low load and transient operation

Power plant stability at lower loads is becoming ever more important, highlighting the increasing requirement for the development of advanced models and tools to analyse and design systems. Such tools enable a better understanding of the thermo-fluid processes and their dynamics, which improves the ability to specify and design better control algorithms and systems. During low load operation and transients, such as start-up and shutdown, the required water flow rate through the evaporator tubes of once-though boilers must be significantly higher than the evaporation rate to protect against overheating of the tubes until once-through operation is reached. Controlling the minimum required water flow rate through the evaporator and economiser is notoriously difficult. Within industry, strong emphasis is placed on maintaining the minimum required flow through the economiser and evaporator without adequate consideration of the potential thermal fatigue damage on the economiser, evaporator and superheater components and the risk of turbine quenching incidents. The purpose of this study was to develop an integrated process and control model that can be used to study transient events. The model developed in Flownex can simulate the complex thermo-fluid processes and associated controls of the feedwater start-up system. This includes the waterrecirculation loop, and allows for detailed transient analysis of the complete integrated system. The model was validated using data from an actual power plant in steady state as well as a transient cold start-up, up to once-through operation. Transient results from the model are also compared to the power plant unit during start-up for the addition or loss of mills using the existing control strategy. The model results compare well with the actual process behaviour. A new control strategy was then proposed and tested using the model. The results indicated significant improvement in control performance and overall controllability of the start-up system, and the large temperature fluctuations currently experienced at the economiser inlet during transients were significantly reduced. The new control strategy was also implemented on a real power plant unit undergoing commissioning. During all modes of start-ups (cold, warm and hot), as well as transients, the performance of the control system showed significant improvement, with a notable decline in instabilities of the feedwater flow. As predicted in the model, the large temperature fluctuations are significantly reduced. The new model therefore enabled the development of an improved control strategy that reduces damaging thermal fatigue. The general controllability of transients is also significantly improved, thereby minimizing risks of water carry-over, quenching and unit trips during start-up