Model-based load demand control

• US 10,190,766 B2
• Filed: 10/19/2015
• Issued: 01/29/2019
• Est. Priority Date: 10/31/2011
• Status: Active Grant

• Current Assignee: Emerson Process Management Power & Water Solutions Incorporated (Emerson Electric Company)
• Original Assignee: Emerson Process Management Power & Water Solutions Incorporated (Emerson Electric Company)
• Inventors: Beveridge, Robert Allen
• Primary Examiner(s): Kasenge, Charles R
• Application Number:
  US14/887,039
• Publication Number:
  US 20160040871A1
• Time in Patent Office: 1,198 Days
• CPC Class Codes: F01K 13/02 Controlling, e.g. stopping or starting
• CPC Class Codes: F22B 35/00 Control systems for steam boilers for fluidized bed boilers F22B31/0076; regulation or control of steam power plants F01K7/00; for regulating feed-water supply F22D; for controlling superheat temperature F22G5/00; control of combustion F23N; regulating or controlling in general G05
• CPC Class Codes: G05B 11/16 Two-step controllers, e.g. with on/off action
• CPC Class Codes: G05B 11/18 Multi-step controllers
• CPC Class Codes: G05B 11/42 for obtaining a characteristic which is both proportional and time-dependent, e.g. P. I., P. I. D.
• CPC Class Codes: G05B 13/04 involving the use of models or simulators
• CPC Class Codes: G05B 13/041 in which a variable is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 13/042 in which a parameter or coefficient is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 17/02 electric

Abstract

Embodiments of methods and systems for controlling a load generated by a power generating system may include controlling at least a portion of the system using model-based control techniques. The model-based control techniques may include a dynamic matrix controller (DMC) that receives a load demand and a process variable as inputs and generates a control signal based on the inputs and a stored model. The model may be configured based on parametric testing, and may be modifiable. Other inputs may also be used to determine the control signal. In an embodiment, a turbine is controlled by a first DMC and a boiler is controlled by a second DMC, and the control signals generated by the first and the second DMCs are used in conjunction to control the generated load. Techniques to move the power generating system from Proportional-Integral-Derivative based control to model-based control are also disclosed.

Claims

1. A method of controlling a load generated by a power generating system, comprising:

receiving, at inputs of a first dynamic matrix controller, a signal indicative of a current value of a first process variable used in a first section of the power generating system and a signal indicative of a target load demand, the first section of the power generating system corresponding to one of a turbine or a boiler;

determining, by the first dynamic matrix controller, a value of a first control signal by inputting a value of the target load demand and the current value of the first process variable into a model stored in a memory of the first dynamic matrix controller, the model being descriptive of a behavior of a process response at various values of load demands;

generating, by the first dynamic matrix controller, the first control signal; and

controlling the load generated by the power generating system based on the first control signal and a second control signal generated by a second dynamic matrix controller based on a current value of a second process variable used in a second section of the power generating system and the target load demand, the second section of the power generating system corresponding to the other one of the turbine or the boiler.

2. The method of claim 1:

further comprising receiving a signal indicative of a setpoint of the first process variable used in the first section of the power generating system; and

wherein determining the value of the first control signal is further based on the signal indicative of the setpoint of the first process variable.

3. The method of claim 2, wherein

the method further comprises:

receiving the signal indicative of the target load demand, a signal indicative of a setpoint of the second process variable corresponding to the second section of the power generating system, and a signal indicative of the current value of the second process variable at inputs of the second dynamic matrix controller;

determining, by the second dynamic matrix controller, a value of the second control signal by inputting the value of the target load demand into a second model stored in a memory of the second dynamic matrix controller, and by using the signal indicative of the setpoint of the second process variable, the signal indicative of the current value of the second process variable, and the second model; and

generating, by the second dynamic matrix controller, the second control signal.

4. The method of claim 1, wherein one of the first process variable or the second process variable corresponds to a throttle pressure within the power generating system, and the other one of the first process variable or the second process variable corresponds to an amount of fuel delivered to the power generating system.

5. The method of claim 2, wherein determining the value of the first control signal is further based on an additional signal that is indicative of a current value of a disturbance variable and that is received at a respective input of the first dynamic matrix controller.

6. The method of claim 5, wherein determining the value of the first control signal based on the additional signal indicative of the current value of the disturbance variable comprises determining the value of the first control signal based on a signal indicative of at least one of:

an amount of soot, a steam temperature, or an amount of burner tilt.

7. The method of claim 1, further comprising:

determining at least a portion of a configuration of the model based on parametric testing of at least a part of the power generating system; and

storing the model in the memory of the first dynamic matrix controller.

8. A method of controlling a load of a power generating system, comprising:

receiving, at a first dynamic matrix controller, a signal indicative of a current value of a first variable and a signal indicative of a desired value of the first variable, the first variable corresponding to one of a turbine or a boiler of the power generating system;

receiving, at a second dynamic matrix controller, a signal indicative of a current value of a second variable and a signal indicative of a desired value of the second variable, the second variable corresponding to the other one of the turbine or the boiler of the power generating system;

generating, by the first dynamic matrix controller, a first control signal based on a target load demand, the signal indicative of current value of the first variable, the signal indicative of the desired value of the first variable, and a first model stored in a memory of the first dynamic matrix controller, the first model being descriptive of a behavior of a process response at various values of load demands;

generating, by the second dynamic matrix controller, a second control signal based on the target load demand, the signal indicative of the current value of the second variable, the signal indicative of the desired value of the second variable, and a second model stored in a memory of the second dynamic matrix controller; and

controlling the load of the power generating system based on the first control signal and on the second control signal.

9. The method of claim 8, wherein controlling the load of the power generating system based on the first control signal and on the second control signal comprises:

controlling one of a throttle pressure within the power generating system or an amount of fuel delivered to the power generating system based on the first control signal, and

controlling the other one of the throttle pressure within the power generating system or the amount of fuel delivered to the power generating system based on the second control signal.

10. The method of claim 8,

further comprising initiating a cessation of a PID (Proportional-Integral-Derivative) control routine within the power generating system, wherein the PID control routine is based on the first variable;

and

wherein generating, by the first dynamic matrix controller, the first control signal based on the first variable occurs after the cessation of the PID control routine based on the first variable has been initiated.

11. The method of claim 8, wherein the first variable is a first process variable, the second variable is a second process variable, and at least one of:

generating the first control signal is further based on a signal indicative of a current value of a first disturbance variable received at the first dynamic matrix controller;

generating the first control signal is further based on a signal indicative of a current value of a first manipulated variable received at the first dynamic matrix controller;

generating the second control signal is further based on a signal indicative of a current value of a second disturbance variable received at the second dynamic matrix controller;

or

generating the second control signal is further based on a signal indicative of a current value of a second manipulated variable received at the second dynamic matrix controller.

12. A power generating system, comprising:

a first dynamic matrix controller including;

respective inputs to receive a signal indicative of a target load demand for the power generating system and a signal indicative of a current value of a first process variable used in one of a turbine or a boiler of the power generating system,

a memory storing a first model, wherein the first model is descriptive of a behavior of a process response at various values of load demands,

a first dynamic matrix control routine configured to determine a value of a first control signal based on the first model, the current value of the first process variable, and a value of the target load demand, and

an output to provide the first control signal to control a load generated by the power generating system; and

a second dynamic matrix controller including;

respective inputs to receive the signal indicative of the target load demand for the power generating system and a signal indicative of a current value of a second process variable used in the other one of the turbine or the boiler of the power generating system,

a memory storing a second model,

a second dynamic matrix control routine configured to determine a value of a second control signal based on the second model, the current value of the second process variable, and the value of the target load demand, and

an output to provide the second control signal to control the load generated by the power generating system in conjunction with the first control signal.

13. The power generating system of claim 12, wherein:

the first dynamic matrix controller further includes a respective input to receive a desired value of the first process variable; and

the first dynamic matrix control routine is configured to determine the value of the first control signal based on the first model, the value of the target load demand, the current value of the first process variable, and the desired value of the first process variable.

14. The power generating system of claim 13, wherein the first dynamic matrix control routine is configured to determine the value of the first control signal based on the first model, the value of the target load demand, the current value of the first process variable, the desired value of the first process variable, and a current value of a disturbance variable used in the power generating system.

15. The power generating system of claim 14, wherein the current value of the disturbance variable corresponds to at least one of:

an amount of soot blowing, a steam temperature, or an amount of burner tilt.

16. The power generating system of claim 13, wherein:

the second dynamic matrix controller further includes;

a respective input to receive a signal indicative of a desired value of the second process variable, and

the second dynamic matrix control routine is configured to determine the value of the second control signal based on the second model, the value of the target load demand, the current value of the second process variable, and the desired value of the second process variable.

17. The power generating system of claim 12, wherein the first dynamic matrix controller and the second dynamic matrix controller are sequentially activated.

18. The power generating system of claim 12, wherein the first model stored in the memory of the first dynamic matrix controller is modifiable in real-time.