Power Station and Process Control Systems

Modern Control Algorithms in Process Control Systems

Observer-based State Control

Contents Modern Control Algorithms in Steam Generator and Auxiliary Plant Control Calculation-guided Closed-loop Control Systems Observer-based State Control Unit Model (Steam Generator and Turbine) Fuzzy Control Algorithms Practical Utilization PID Controller versus State Controller with Observer Performance Comparison using an Application Example Conventional State Controller with Observer Mauell State Controller with Observer (MZR)

Page

4 4 5 5 5 6 6 7 8

Tools for the Calculation of the Controlled System Parameters 9 Measuring Value Acquisition of the Controlled System Response Identification of the Controlled System and Indication of the Characteristic Parameters Load Level Balancing of the Superheater Time Response Comparison Between PID and MZR PID Controller Mauell State Controller (MZR) Retrofitting Projects Conclusions 10 10 11 12 12 14 15 15

Observer-based State Control

Modern Control Algorithms for Steam Generator and Auxiliary Plant Control

District heating

3 1 5 6 4
Heat value correction
G

- Brown coal - Refuse

1 Unit model (smooth load control) 2 Condensate stop control 3 Calculation-guided control Unit control concept and use of modern control algorithms

4 Fuzzy control 5 Turbine speed and power control 6 Observer-based state control

Calculation-guided Closed-loop Control Systems Fields of application and characteristics Condensate stop control District heating supply from cogeneration Calculation-guided closed-loop controls are primarily used in complex power station heat circuits where often contrasting task definitions have to be taken into account: Fast and opposite load variations at the consumer end, e.g., turbines / generator and district heating system Slow increase of the steam generator output Using conventional closed-loop control circuits responding to system deviations, these tasks can only be solved with a maximum effort in the planning and commissioning phases. They also hinder a dynamic operation of the plant. The block model assigns parameters on the basis of the technological design specifications, supplies reference input variables for all control loops of the meshed system - right up to the

furnace operation setpoint control. Model errors are corrected by the secondary setpoint controllers of all major process areas, such as FD floating pressure, turbine extraction pressure, heating condenser pressure. Observer-based State Control Field of application and characteristics Live steam temperature control Intermediate superheater temperature control Control loops with highly load-dependent time constants and of higher system order The state controller with observer is used for higher-level processes with self-regulation, but can also be used for processes with dead time. The process/plant-specific disturbance analysis is carried out by an internal state observer and the analysis result is taken into account when the manipulated variable is generated. Actuator non-linearity, system dead time, etc. are taken into account by internal compensation circuits so that a persisting system deviation is avoided. An online parameter adaptation derives the optimal

Observer-based State Control

state controller parameters from the controlled system characteristics. The use of a state controller results in an aperiodic and asymptotic damping of the controlled variable characteristics which leads to a smooth actuator operation and therefore a smooth response of the linked variables.

The method of multi-variable control based on a Fuzzy algorithm can be used for non-linear and linear processes. Reference setpoints are derived from the various actual values for all furnacerelevant control loops (e.g., control of the roller/ travelling grate speed, primary/secondary/tertiary air quantities, refuse feeding speed, backup firing).

Practical Utilization Unit Model (Steam Generator and Turbine) Fields of application and characteristics Anticipation of the boiler and turbine output development, gradient limiting for the load balancing through the block capacity control (to avoid irregular block operation). Large-scale power station components only allow certain load characteristics. A setpoint control that is not optimally adjusted to the possible actual conditions will lead to unnecessary fluctuations in the control response and thus to unauthorized controller actions. This puts unnecessary strain on the materials and reduces plant efficiency. If the time characteristics for the setpoint control of the essential components is derived on the basis of plant-specific parameters (load level setpoint gradient, storage capacity, etc.), the block model can be used to implement a specific setpoint control of all large-scale components which takes into account the actual process conditions. This will result in an optimal utilization of the dynamic performance and a higher overall efficiency at load variations. Untimely correction of the control process through the secondary setpoint control systems can be avoided. The described control strategies are implemented on the standard processors of the ME 4012 process control system so that the practical utilization of these modern control concepts is greatly facilitated.

Fuzzy Control Algorithms Fields of application and characteristics FGD plant optimization of the deposition degree of the SO2 content in the raw gas by selecting and specifying the number of the spraying levels in operation Correction of the furnace operation control due to fluctuations in the heat value and mass current measurement errors, e.g., solid waste or refuse-fired furnace. Plant areas producing inconsistent process variable fluctuations which cannot be measured are difficult to control satisfactorily, even if complex control loops with a high degree of intermeshing and complex feedforward control are employed. The calorific value of refuse or brown coal, for example, cannot be determined satisfactorily due to the fluctuations in the composition of these fuels. The operation of incinerators in particular requires various fuelling parameters to be taken into account in order to achieve a high energy utilization factor. Such parameters would be, for instance, the furnace temperature range, the minimum retention time of the gaseous products at specific temperatures, air excess or starvation in the various burning zones, the quality of the steam parameters.

Observer-based State Control

PID Controller versus State Controller with Observer

PID Controller versus State Controller with Observer Analog, standard algorithm PID control on a pneumatic, hydraulic or electronic basis has proved its worth over many years, and is still first choice in daily control circuit design even in the days of digital process control systems. Despite the fact that the PID controller structure is not adapted to the controlled process and its setting parameters do not allow to draw direct conclusions on the control quality, points in favour of its use are the detailed knowledge on how the PID controller works, and the many years of experience that provide plant engineers with the intuitive feel for tuning. In this report, we confront the well-established technique (PID control) with the new technique (observer-based state control) and show that an alternative exists for the PID controller that is equally practical but more robust to unpredictable changes in the behaviour of the controlled system (e.g., superheater processes). Based on the state controller described in technical literature and many application reports, Mauell extended the observer concept of the state controller by implementing essential features that have not been fully documented in the past. Essential modules of the observer concept: State observer Disturbance observer Actuator observer User-friendly and objective parameter setting and optimization concept Performance Comparison using an Application Example In this section we compare the performance of a Mauell state controller with that of a PID controller. In our example the controllers are used for the live steam temperature control of a steam generator, which is characterized by large and highly loaddependent time constants, a higher system order (n = 3....5 typ.), external disturbances due to fluctuations in the heating of the superheater, and high demands on the control quality. The application example will also demonstrate the versatility of the Mauell state controller with respect to the fields of application and its suitability for all aperiodic systems with compensation or dead times. It will show that the state controller offers clear advantages when used in higher-order systems and control loops with long dead times and actuator-dependent non-linearities. The effect of the two alternative control concepts is illustrated for a steam generator with a two-line superheater (see figure below).

Dead time compensation

Example of a steam generator with a two-line superheater, displayed on the ME-VIEW operator control and monitoring system. Line 1 is equipped with a PID controller, line 2 with state controller. 6 Observer-based State Control

In the following we will only look at the structure of the Mauell state controller as the structure and principle of operation of the PID controller is common knowledge. We start with a summary of the concept of conventional observerbased state control so that you will be able to compare it with the Mauell state controller and easily recognize its advantages and innovative features. Conventional State Controller with Observer The figure below shows the basic structure of a conventional state controller with state observer and secondary injection controller implemented in a 3rd order controlled system. From a complete set of state variables that clearly describe the system state, the conventional state controller generates a manipulated variable by means of linear combination. Owing to the fact that only the state variable can be measured, the state observer derives the other required state variables T1 and T2 and transmits them to the state controller. The variable T3 is derived by the state observer and is the equivalent to the system deviation Ta = Ta - Ta, soll. From the observer deviation Ta -T3 and the input variable Te, the state observer then tries to determine the external disturbances (manipulated-variable independent changes of the output variable) on the controlled system.

However, this conventional state control has the following shortcomings: The state observer cannot fully compensate for the observation error Ta - T3 and is thus not able to completely reproduce the required state variables. In the steady state, the state controller produces a permanent control deviation. Adaptation of the internal parameters to the load is practically not possible. The state controller is adapted to the structure of the controlled system. However, as secondary control loops and actuators with their mostly non-linear behavior are also part of the system to be controlled, they too must be taken into account. Adaptation is therefore more difficult to achieve and the controller adjustment is less exact. Dead times of the controlled system cannot be taken into account. There is no tool for user-friendly and objective parameter setting and optimization. The commissioning of the conventional state controller therefore requires extensive knowledge of the state space representation. We see that the practical use of the conventional controller is limited because of the drawbacks described above. Also, plant designers and commissioning engineers, even the service personnel, must have special knowledge of state space systems.

Te

Ta

- Ta soll
State observer

DTa
+ -

x
+

h1

x
+
T1

h2

x
+
T2

h3

T3
k2

x
Te, soll

k1

x
+

k3

PI

+
State controller

Conventional state controller with observer Observer-based State Control 7

PID Controller versus State Controller with Observer

Mauell State Controller with Observer (MZR) The Mauell state controller has inherited the basic structure of the conventional state controller which has been extended by additional structural features. These new features are described in the following. Elimination of the Steady-state Observer Error In order to eliminate the steady-state observer error (Ta - T3), the basic structure of the observer concept is extended by a disturbance observer so that the observer error Ta - T3 converges towards zero. Elimination of the Steady-state System Deviation For known disturbances on the controlled system, the steady-state deviation of a state controller can be determined from the transfer function of the controlled system and the parameters of the state controller. As the disturbances are statically mapped by the state observer, it is possible to evaluate the contents of the integrator and as a result compute the change of the state controllers state variable in order to eliminate the steady-state system deviation. In this context, the reference input variable can also be considered as a disturbance in the sense of a shift of the neutral position. These observations formed the basis for the development of the Mauell state controller. To make the state controller robust to non-linear variations of the follower controller and actuator, a so-called actuator observer has been implemented. The actuator observer has the task of varying the state variables T1 to T3 so that they can be used for the determination of the state controllers manipulated variable without showing any signs of the secondary control loops dynamic behavior. Therefore, within the framework of the overall cascade, the secondary control loop has only a delaying effect. It does not affect the stability of the state controller. The additive connection of the state observers integrator output for the elimination of the steady-state deviation is expressed by the factor k0. As the calculation of the factor k0 takes the transfer function of the controlled system into account, inaccuracies in the elimination of the system deviation must be expected. Due to the fact that deviations in the steady state between the controlled system and the model in the state observer are taken into account by the disturbance observer, model errors, especially gain factor deviations, have no influence on the control precision of the steady-state controlled system. Compensation of the Non-linearities of Secondary Follower Controllers and Actuators

Te

Ta

Ta,soll
Load balancing

Disturbance observer

State observer

System parameters:

n Order

h0

h1

h2

h3

ks Gain T Denominator
time constant

T 1

T 2 k1 k2

T 3 k3

Tt Dead time Tz Numerator

time constant

State controller

X PI

k0

from the system identification model

X
-

l1

l2

l3

Actuator observer

Speed

Mauell state controller (implemented in a 3rd order controlled system) with its internal structure adapted to the order of the controlled system 8 Observer-based State Control

Dead Time Compensation of the Controlled System The actuator observer divides the entire feedback system into the two decoupled subsystems PI follow-up control and State setpoint control. If the controlled member of the setpoint control (in our example this is the superheater) has a dead time (from the superheater inlet temperature Te to the outlet temperature Tt), this cannot be taken into account by the state observer. This will also be compensated for by the actuator observer. The actuator observer represents the third decoupled subsystem, the so-called Dead time system. Like the secondary PI follow-up control, it has only a delaying effect on the feedback control (corresponding to the dead time) and does not in any way affect the stability of the state controller. Tools for the Calculation of the Controlled System Parameters and the Optimization of the Mauell State Controller Parameters A concept had to be developed that allows to determine the controlled system parameters n, k, T and Tt and to set up and optimize the controller parameters in a convenient and practical way. This concept was implemented in the Mauell controller setup tool AE 4012BS-EH. A special algorithm based on online computing of the numerous parameters of the disturbance quantities, actuator and state observers and state controller and its integration in the Mauell state

controller, obtains the following controlled system parameters by applying a step change and recording the response to this step change: n = Order k = Gain T = Time constant Tt = Dead time Function generators adapt these parameters to the current operating point as a function of load. The only parameter of the Mauell state controller that remains to be set is the speed factor V. This parameter defines by what factor the feedback control loop is to be faster than the controlled system. Next, we shall briefly discuss the steps to go through to determine the controlled system parameters.

Controlled system
Controlled system model

Step change
inquiry

System parameters: - System order n - Gain factor k s - Denominator time constant Tn - Numerator time constant Tz - Dead time Tt

MU

analog A D Y

D A

Controller model
W

Controller in PLS

Kp

tn

tv

Setpoint generator

Structure of the controlled system and controller model generation for the optimization of the setting parameters Observer-based State Control 9

PID Controller versus State Controller with Observer

Measuring Value Acquisition of the Controlled System Response The measuring value acquisition records the response of the controlled system to a step change of the manipulated variable. Before the step change is applied the controlled system must be in the steady-state condition, or at master controller optimization, the follow-up control (e.g., inlet temperature control) must operate in automatic mode. The amplitude of the step input to the manipulated variable should differ clearly from that of any superimposed disturbances. While the measuring values are being recorded, the diagram axes are automatically zoomed and scaled to offer a good overview of the measured data. The transfer function of the Measuring value acquisition of a step response controlled system is obtained when the controlled system has settled and returned to the steady- Identification of the Controlled System and Indication of the Characteristic Parameters state following the application of the step change. The data record of the measured values can now be saved together with a comment (e.g., the corresponding load point or operating point). A mathematical model is created from the measuring data set of the controlled system step response that clearly describes the dynamic behavior of the controlled system. Via menu the stored measuring values are loaded for the identification of the controlled system together with their time specification and recording information. The actual identification starts with the marking of the point of time when the step change was applied (change of the manipulated variable). The automatic determination of the model parameters is completed as soon as the optimal model quality is reached, i.e., if the error area between the simulated behavior of the controlled system on the basis of the mathematical model and the measuring data set of the step response is at a minimum. The parameters of the controlled system are also displayed. After the identification of the controlled system, the parameter set of the controlled system model can be stored together with a comment for documentation purposes. System identification during the computing of the step response with mathematical description 10 Observer-based State Control

Load Level Balancing of the Superheater Time Response The derived values can be used directly for adjusting the Mauell state controller. Only the time constant T is varied loaddependently, as shown in the figure, based on the assumption that the time constant T changes inversely proportional to the steam quantity. This behavior results from the higher steam flow velocities at a high steam quantity. The parameters for the Mauell state controller can be set online by directly transmitting the derived values.

Load level balancing

Graphical configuration interface with online process data for entering the controlled system parameters as well as the speed factor V.

Observer-based State Control

11

PID Controller versus State Controller with Observer

Comparison between PID and MZR PID Controller The alternative control loop with PID controller has also been optimized on the basis of the data of the controlled system identification. Supplementary to the procedure for the state controller, the program module Controller Design has been employed. The program module Controller Design allows you determine optimal parameters for P, I, PI, PD and PID controllers on the basis of the system model from the controlled system identification. The first step is to select the system model of the Controlled system identification process. The program loads a graphical representation of the system model. The desired control algorithm is specified by enabling the parameters (kp, Tn, Tv). The control quality can be specified by entering the maximum overshoot and adapting the dynamic behavior of the actuator signal to that of the actuator. Also, only moderate actuator speeds should be selected to avoid unnecessary wear of the servo drive and gland. The optimization procedure starts with the simulation of the closed control loop as a response to a step change of the reference variable. The program provides you with a continuous graphical representation of the optimization sequence. The optimization procedure is completed as soon as the specified quality criteria are reached, supplying the optimal controller setting parameters (see diagram below): P component I component D component Proportion. coefficient kP Reset time Tn [s] Setup time TV [s]

Deriving the optimal setting parameters kp, Tn, Tv for a PID controller with the help of the Controller Setup Tool 12 Observer-based State Control

Optimization Complexity The PID controller tuning is based on the characteristic quantities n, k, T and the parameter T of the controlled system. These parameters can be determined in a convenient and straightforward way using the AE4012BS-EH controller setup tool, and adjusted load-dependently. Using the program module Controller Design, the PID controller can be optimized by deriving optimal kp, Tn and Tv parameters. Assessment of the PID Controller The controller results can be characterized as follows: Rise time Settling time Overshoot Error area Actuator movement Commissioning Longer than for the MZR Longer than for the MZR Depending on the parameter adaptation Larger than for the MZR Uneven, highly intervening Similar to the MZR, more complex for highly nonlinear systems Partially controllable through controlled adaptation of the parameters kp, Tn, Tv (very complex)

Operating point dependency

Detail diagram of the PID controller in the ME-VIEW operator control and monitoring system (line 1 of the superheater) Observer-based State Control 13

PID Controller versus State Controller with Observer

Mauell State Controller (MZR) The analysis of the model parameters n and k and the loaddependent parameter T specified for the state controller revealed a very good model adaptation. The advantages of the actuator observer have been proved true as only the superheater behavior from the superheater inlet temperature to the superheater outlet temperature had to be taken into account for the parameter assignment of the state controller. Possible variations from the secondary injection control, the injection cooler and the actuator, are not taken into account in this model. This increases the model quality considerably as difficult to model nonlinearities can be neglected. The initially selected presetting for the speed factor V (initial value 1.5), that corresponds to the maximum value of the concurrent PID controller, could be increased to the speed factor V = 3.5. Optimization complexity The Mauell state controller tuning is based on the characteristic quantities n, k, T and the parameter Tt of the controlled system. These parameters can also be determined using the AE4012BSEH controller setup tool, and adjusted load-dependently. The speed factor V is the only setting parameter that affects the dynamic behavior of the control loop. The adaptation of this parameter does not require any specific knowledge. It was not necessary to implement feed forward control. Assessment of the Mauell State Controller The controller results can be characterized as follows: Rise time Setting time Overshoot Shorter than for the PID Much shorter than for the PID 0%, always with asymptotic damping and thus a good condition for a smooth process Much smaller than for the PID Accurate, even, allowing temperature adjustment with minimum feed water quantity. Similar to the PID Can be compensated for by adjusting the load-dependent system time constant T.

Error area Actuator movements

Commissioning Operating point independence

Detail diagram of the MZR controller in the ME-VIEW operator control and monitoring system (line 2 of the superheater) 14 Observer-based State Control

Measured data monitoring [C] TA - Tr/SC TA - Tr/PID TWA - Tr : Outlet temperature

TSetpoint

[t/h] FEW/PID

Time

FEW : Injection water quantity

FEW/SC

Momentarily superposed control (interfering) command. The commands are set off with a time delay to get clear readings.
Time

Qualitative comparison of the controller results TA - Tr / ZR (state controller) and TA - Tr PID (PID controller)

Retrofitting Projects The state controller with observer can be retrofitted to boilers with conventional process control system (hard-wired control and analog feedback system with control console operating elements) as well as to newer plants with digital process control system and video terminals, simply by integrating a module of the ME 4012 digital process control system in the existing control systems. The existing connections between the control room, controller modules and servo drives remain unchanged. The integration can be carried out while the system is operating provided the necessary preparations have been made. It is also possible to integrate the Mauell state controller on the basis of a Mauell hardware platform so that the plant operator is provided with the familiar operator control and signalizing concept. The communication with the third-party system is established over a serial or parallel-wire connection. The parameters can be assigned online.

Conclusions The above comparison between a PID controller and a Mauell state controller showed that the Mauell state controller with observer has clear advantages when used in complex systems that would be difficult to control using standard algorithms. The control behavior illustrated in the example has been verified by concrete industrial applications and proven its worth. Mauell observer-based control is for example implemented since October 1996 in block 5 (coal-/oil-fueled, 420t/h steam capacity) of the Hafen power plant, Stadtwerke Bremen AG. Other applications, like for example the four boilers and the 1000t/h steam generator of the waste-fueled power station of AWG Wuppertal, confirm the successful employment of the Mauell state controller with observer.

Observer-based State Control

15

Representatives

Power station control and process control Power distribution control, station control and remote control Automation and communication systems Industrial automation and building systems automation Alarm indication, event recording and annunciator systems Mosaic systems, control room technology and large-screen projection Engineering, installation, commissioning, maintenance and training
Helmut Mauell GmbH Am Rosenhgel 1-7 D-42553 Velbert Germany Tel. +49 (0)20 53 1 30 Fax +49 (0)20 53 1 34 03 E-Mail info@mauell.com Helmut Mauell B.V. Postbus 89 NL-3840 AB Harderwijk Netherlands Tel. +31 (0)3 41 41 15 80 Fax +31 (0)3 41 41 15 81 E-Mail info@mauell.nl Helmut Mauell GmbH Nov 967 CZ-28522 Zruc nad Szavou Czech. Republic Tel./Fax +420 (0)3 27 93 42 80 Mobiltel. 06 02 38 97 70 E-Mail mir-v@cboc.cz

Werk Weida Papiermhlenweg 10 D-07570 Weida Germany Tel. +49 (0)3 66 03 4 80 Fax +49 (0)3 66 03 4 83 10 E-Mail kle@mauell.com

Mauell GmbH Triester Strae 10/1/121 A-2351 Wiener Neudorf sterreich Tel. +43 (0)22 36 2 11 01-0 Fax +43 (0)22 36 2 11 01-30 Mobiltel. +43 (0) 664 14 28 371 E-Mail fje@mauell.at

Helmut Mauell GmbH SULTAN INTERNATIONAL P.O. Box 3486 Abu Dhabi U.A.E. Tel. +9712 6 22 44 11 Fax +9712 6 22 44 55 E-Mail farag@emirates.net.ae

Mauell AG Furtbachstrae 17 CH-8107 Buchs Switzerland Tel. +41 (0)1 847 42 42 Fax +41 (0)1 844 44 56 E-Mail info@mauell.ch

Mauell Ltd. P.O. Box No. 183 GB-Calne, SN11 9BZ Wiltshire/Great Britain Tel. +44 (0)12 49 81 20 46 Fax +44 (0)12 49 81 70 96 E-Mail mauell@globalnet.co.uk

Mauell Corporation 31 Old Cabin Hollow Road Dillsburg PA 17019 USA Tel. +1717 4 32 86 86 Fax +1717 4 32 86 88 E-Mail gms@mauell-us.com

To obtain our latest list of branch offices and sales representatives in both Germany and abroad: visit us at: www.mauell.com email us at: info@mauell.com or call us: +49 (0) 20 53 - 13 405 please adress technical inquiries to: vertrieb@mauell.com

Helmut Mauell do Brasil Ltda. Estr. Est. Salvador de Leone, 2998 06850-000 Itapecerica da Serra So Paulo / Brazil Tel. +55 (0)11 79 47-17 77 Fax +55 (0)11 79 47-17 74 E-Mail mauell@mauell.com.br

01.4012.33E00