Model based control as an add-on for PID controllers · 2014. 11. 17. · • Advanced-PID combustion control deliver excellent results • For cases with strongly different waste

GemeinschaftskraftwerkSchweinfurt GmbH

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

Model based control for advanced PID combustion controllers in WtE plants


2NGBW-Conference

Oslo, 16.-17.02.2010

GKS Gemeinschaftskraftwerk Schweinfurt GmbH

- Waste-to-Energy Section -


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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


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Manipulable Variables: 18!


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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)


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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


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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


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Overview new advanced combustion control system


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Plant limits and base tables

…


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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


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!


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Oslo, 16.-17.02.2010

Idea: Model for Combustion Chamber


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Oslo, 16.-17.02.2010

Model Structure


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Combustion model


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Connection of Model to CCS via OPC


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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


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Oslo, 16.-17.02.2010

Bed height + manipulated Variable

Extended bed height with instable combustion was avoided!


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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)


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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


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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


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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

Documents

Model based control as an add-on for PID controllers · 2014. 11. 17. · • Advanced-PID combustion control deliver excellent results • For cases with strongly different waste