Model based control as an add-on for PID controllers · 2014. 11. 17. · • Advanced-PID...

GemeinschaftskraftwerkSchweinfurt GmbH

Dr.-Ing. Ragnar Warnecke and Volker Müller GKS, Germany

Model based control for advanced PID combustion controllers in WtE plants

GemeinschaftskraftwerkSchweinfurt GmbH

2NGBW-Conference

Oslo, 16.-17.02.2010

GKS Gemeinschaftskraftwerk Schweinfurt GmbH

- Waste-to-Energy Section -

GemeinschaftskraftwerkSchweinfurt GmbH

3NGBW-Conference

Oslo, 16.-17.02.2010

2

3

4 5

6

1

60%

100%

110% 2' 1'

6'

60%

100%

110%

5'4'67%

8,00

10,00

12,00

14,00

16,00

18,00

20,00

22,00

24,00

26,00

3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 11.000

Fuel

Cap

acity

[MW

]

Fuel Throughput [kg/h]

Firing Capacity Diagram

Rev. 1 25.07.2006

GKS Schweinfurt GKS-06-001-"2006"

Auxillary burners

Area of normal Operation

Shortterm Overload Capacity

Important to meet the given capacity data

Good combustion control system necessary

GemeinschaftskraftwerkSchweinfurt GmbH

4NGBW-Conference

Oslo, 16.-17.02.2010

Manipulable Variables: 18!

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5NGBW-Conference

Oslo, 16.-17.02.2010

Kinds of Combustion Control Systems

Combustion ControlSystems (CCS)

Fuzzy Control (FC)

Neuronale Artificial Network

(NN)

PID Model Controlled(MC)

Conventional Advanced

Neuronal StatisticNet

Model BasedFuzzy Support

Model Predictive Control(MPC)

GemeinschaftskraftwerkSchweinfurt GmbH

6NGBW-Conference

Oslo, 16.-17.02.2010

Decision matrices

Control systems:→Arguments:↓

PID FC NN MPC

Experience of GKS control engineer ++ 0 -- --Acceptance of GKS operators ++ + 0 0Physical/chemical/technical understanding by GKS staff

++ + 0 +

Reference situation of the suppliers in WtE-plants ++ + - -Changes by GKS possible (without others) ++ -- -- --Perspective in the future ++ 0 + ++

Companies:→Arguments:↓

SAR,Dingolfing

Babcock-Noell, Würzburg

Thyssen-Krupp, KH-Automation, Fuldabrück

References in WtE-plants

++ ++ 0 -

Competence in discussion (controller/proce

ss engineering)

++ ++ + --

Flexibility for integration of MBC

++ + - -

Detail solutions ++ ++ + +Price ++ ++ 0 0

GemeinschaftskraftwerkSchweinfurt GmbH

7NGBW-Conference

Oslo, 16.-17.02.2010

Integration of CC into DCS

Profi-bus

Hydraulic-system control

Bus-System CS 275

Hydraulic-system control

Profi-bus

Gateway

Hydraulic-system controlProfi-bus

Linie 11 Linie 12

Engeneering-Station

Linie 13

Gateway Gateway

AS: PCS7 + ServerAS: PCS7 + Server

AS: PCS7 + ES

Remote-maintenance

Office-network

GemeinschaftskraftwerkSchweinfurt GmbH

8NGBW-Conference

Oslo, 16.-17.02.2010

Overview new advanced combustion control system

GemeinschaftskraftwerkSchweinfurt GmbH

9NGBW-Conference

Oslo, 16.-17.02.2010

Plant limits and base tables

…

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10NGBW-Conference

Oslo, 16.-17.02.2010

Comparison of Data

0

2

4

6

8

10

12

14

-15 -13,8 -12,6 -11,4 -10,2 -9 -7,8 -6,6 -5,4 -4,2 -3 -1,8 -0,6 0,6 1,8 3 4,2 5,4 6,6 7,8 9 10,2 11,4 12,6 13,8 15

num

ber o

f val

ues

[%]

deviation actual value of steam production to set point [%]

new combustion control system old combustion control system

0

1

2

3

4

5

6

7

8

0,2 1 1,8 2,6 3,4 4,2 5 5,8 6,6 7,4 8,2 9 9,8 10,6 11,4 12,2 13 13,8 14,6 15,4 16,2 17 17,8 18,6 19,4 20

num

ber o

f val

ues

[%]

CO concentration [mg/m³]

new combustion control system old combustion control system

GemeinschaftskraftwerkSchweinfurt GmbH

11NGBW-Conference

Oslo, 16.-17.02.2010

Extended Bed Height (< 0,5 % of operation time)

‐

10,00   

20,00   

30,00   

40,00   

50,00   

60,00   

70,00   

80,00   

90,00   

100,00   

‐

200,00   

400,00   

600,00   

800,00   

1.000,00   

1.200,00   

1.400,00   

FR Z 1

FR Z 2

FR Z 3

FR Z 4

FR Z 5

Kessel‐Eintritt

Feurerraumtemp. Kesseldecke ohne Offset

SW FD‐Menge L11

L11 Frischdampfmenge

02 Gehalt RG Kesselaustritt  tr.

CO RG K ATR

Loss of efficiency and burden of environment!

GemeinschaftskraftwerkSchweinfurt GmbH

12NGBW-Conference

Oslo, 16.-17.02.2010

Idea: Model for Combustion Chamber

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13NGBW-Conference

Oslo, 16.-17.02.2010

Model Structure

GemeinschaftskraftwerkSchweinfurt GmbH

14NGBW-Conference

Oslo, 16.-17.02.2010

Combustion model

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15NGBW-Conference

Oslo, 16.-17.02.2010

Connection of Model to CCS via OPC

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16NGBW-Conference

Oslo, 16.-17.02.2010

Bed height from ModelBeispielhafter Schichthöhenverlauf über 12 Stunden (vom Modell gerechnet) :

Zone 1

Zone 2

Zone 4

Zone 3

Heizwert

GemeinschaftskraftwerkSchweinfurt GmbH

17NGBW-Conference

Oslo, 16.-17.02.2010

Bed height + manipulated Variable

Extended bed height with instable combustion was avoided!

GemeinschaftskraftwerkSchweinfurt GmbH

18NGBW-Conference

Oslo, 16.-17.02.2010

Summary

• OPC connection works

• Model data are very good validated with real plant

• Control signals of bed height are sent to CCS

• Interpretation of the deviation of real data and model data shows very good results

• GKS will use the signal to avoid male operation during extended bed height (caused by severe waste fluctuation)

GemeinschaftskraftwerkSchweinfurt GmbH

19NGBW-Conference

Oslo, 16.-17.02.2010

Objectives:

Primary objectives: • Advanced-PID combustion control deliver excellent results• For cases with strongly different waste a model can deliver sufficient data to avoid problems in combustion

Overall objectives:• Advanced-PID systems increase efficiency of plants and reduce emissions

• Avoiding instabilities in combustion by MBC coupling eliminate efficiency loss and environmental burden

• A combustion model deliver an enlarged understand of the processes

GemeinschaftskraftwerkSchweinfurt GmbH

20NGBW-Conference

Oslo, 16.-17.02.2010

Economic Goals for ProductsFor the Combustion Control System (CCS): •The Advanced-PID got new structured overview• Dynamic function plans are now integrated• Extended weighting table with more variables are included in the CCS

Advantages by the model:• Model is available for coupling with CFD and CCS• Operation with parallel Model is possible• Pre-adjustment of CCS is possible offside the plant (= faster commissioning)

• Avoiding of failures during operation at the plant by pre-adjustment

GemeinschaftskraftwerkSchweinfurt GmbH

21NGBW-Conference

Oslo, 16.-17.02.2010

Economic and Ecologic Goals for GKS• About 5 % less CO

• About 3 % more throughput (5.000 t/a)

• Much better understanding of the processes

• Chlorine trap: about 25 % decreased corrosion