Steam temperature control using dynamic matrix control

• US 9,335,042 B2
• Filed: 08/16/2010
• Issued: 05/10/2016
• Est. Priority Date: 08/16/2010
• 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 A., Whalen, Richard J. Jr.
• Primary Examiner(s): Tompkins, Alissa
• Assistant Examiner(s): Herzfeld, Nathaniel
• Application Number:
  US12/856,998
• Publication Number:
  US 20120040298A1
• Time in Patent Office: 2,094 Days
• Field of Search: 122/6.R, 432/49, 432/36, 700 28- 37, 700 44- 45, 700/53, 700/209
• US Class Current: 1/1
• CPC Class Codes: F22G 5/12 by attemperating the superheated steam, e.g. by injected water sprays spray mixers B01F25/70

Abstract

A technique of controlling a steam generating boiler system includes using a rate of change of disturbance variables to control operation of a portion of the boiler system, and in particular, to control a temperature of output steam to a turbine. The technique uses a primary dynamic matrix control (DMC) block to control a field device that, at least in part, affects the output steam temperature. The primary DMC block uses the rate of change of a disturbance variable, a current output steam temperature, and an output steam temperature setpoint as inputs to generate a control signal. A derivative DMC block may be included to provide a boost signal based on the rate of change of the disturbance variable and/or other desired weighting. The boost signal is combined the control output of the primary DMC block to more quickly control the output steam temperature towards its desired level.

Claims

1. A method of maintaining an output steam temperature of a steam generating boiler system at a desired output steam temperature setpoint, comprising:

obtaining a signal indicative of a disturbance variable used in a control loop of the steam generating boiler system operating to maintain a temperature of output steam at the desired output steam temperature setpoint, the signal indicative of the disturbance variable generated by a device included in a second portion of the steam generating boiler system, the portion of the steam generating boiler system excluding any devices included in the control loop;

determining a rate of change of the disturbance variable;

providing a signal indicative of the rate of change of the disturbance variable to an input of a dynamic matrix controller;

generating, by the dynamic matrix controller while the control loop of the steam generating boiler system is operating to maintain the temperature of the output steam at the desired output steam temperature setpoint, a control signal for a manipulated variable used in the control loop of the steam generating boiler system, the generating of the control signal for the manipulated variable based on the signal indicative of the rate of change of the disturbance variable and a signal indicative of the desired output steam temperature setpoint; and

controlling, based on the control signal for the manipulated variable, the temperature of the output steam to be maintained at the desired output steam temperature setpoint, wherein the output steam is generated by the control loop of the steam generating boiler system for delivery to a turbine.

2. The method of claim 1, wherein the device is a field device of the steam generating boiler system.

3. The method of claim 2, wherein the field device corresponds to one of a plurality of sections of the steam generating boiler system, the plurality of sections including a furnace, a superheater section and a reheater section.

4. The method of claim 1, wherein obtaining the signal indicative of the disturbance variable includes obtaining a signal corresponding to at least one of:

a furnace burner tilt position;

a steam flow;

an amount of soot blowing;

a damper position;

a power setting;

a fuel to air mixture ratio of a furnace of the steam generating boiler system;

a firing rate of the furnace;

a spray flow;

a water wall steam temperature;

a load signal corresponding to one of a target load or an actual load of the turbine;

a flow temperature;

a fuel to feed water ratio;

the temperature of the output steam;

a quantity of fuel;

a type of fuel, a manipulated variable of the portion of the steam generating boiler system, or a control variable of the portion of the steam generating boiler system.

5. The method of claim 1, wherein obtaining the signal indicative of the disturbance variable includes obtaining multiple different signals, with each of the multiple different signals corresponding to a different disturbance variable.

6. The method of claim 1, wherein generating the control signal comprises generating the control signal further based on a parametric model stored in the dynamic matrix controller.

7. The method of claim 1, wherein the dynamic matrix controller is a first dynamic matrix controller, and the method further comprises:

providing the signal indicative of the rate of change of the disturbance variable to an input of a second dynamic matrix controller;

determining an amount of boost to be added to the control signal; and

generating, by the second dynamic matrix controller, a derivative signal corresponding to the amount of boost based on the rate of change of the disturbance variable; and

wherein controlling the temperature of the output steam based on the control signal for the manipulated variable comprises controlling the temperature of the output steam based on a combination of the derivative signal generated by the second dynamic matrix controller and the control signal for the manipulated variable generated by the first dynamic matrix controller.

8. The method of claim 7, wherein:

generating the control signal by the first dynamic matrix controller comprises generating the control signal further based on a first parametric model stored in the first dynamic matrix controller,

generating the derivative signal by the second dynamic matrix controller comprises generating the derivative signal further based on a derivative parametric model stored in the second dynamic matrix controller, and

the first parametric model and the derivative parametric model are different parametric models.

9. The method of claim 1, wherein the input of the dynamic matrix controller is a first input, and the method further comprises providing a signal indicative of an actual temperature of the output steam to a second input of the dynamic matrix controller and providing the output steam temperature setpoint to a third input of the dynamic matrix controller;

and

wherein generating the control signal comprises generating the control signal based on the signal indicative of the rate of change of the disturbance variable provided at the first input, the signal indicative of the actual temperature of the output steam provided at the second input, and the output steam temperature setpoint provided at the third input.

10. The method of claim 1, wherein determining the rate of change of the disturbance variable comprises:

adding a first time delay to the signal indicative of the disturbance variable to generate a first delayed signal indicative of the disturbance variable;

adding an additional time delay to the first delayed signal to generate a second delayed signal indicative of the disturbance variable; and

using the first delayed signal, the second delayed signal, the first time delay, and the second time delay to determine the rate of change of the disturbance variable.

11. The method of claim 10, further comprising adjusting the at least one of the first time delay or the second time delay.

12. The method of claim 11, wherein adjusting the at least one of the first time delay or the second time delay comprises adjusting the at least one of the first time delay or the second time delay based on the rate of change of the disturbance variable.

13. The method of claim 10, wherein using the first delayed signal, the second delayed signal, the first time delay, and the second time delay to determine the rate of change of the disturbance variable comprises determining a difference between the first delayed signal and the second delayed signal, and using the determined difference to determine the rate of change of the disturbance variable.