Dynamic tuning of dynamic matrix control of steam temperature

• US 9,447,963 B2
• Filed: 02/07/2011
• Issued: 09/20/2016
• 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:
  US13/022,237
• Publication Number:
  US 20120036852A1
• Time in Patent Office: 2,052 Days
• Field of Search: 122/6.R, 122/479.1, 432/13, 432/49, 432/36, 700 28- 37, 700 44- 45, 700/83, 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 dynamically tuning a rate of change of a disturbance variable (DV) to control operation of a portion of the boiler system, and in particular, to control a temperature of output steam to a turbine. The rate of change of the DV is dynamically tuned based on a magnitude of an error or difference between an actual and a desired level of an output parameter, e.g., output steam temperature. In an embodiment, as the magnitude of the error increases, the rate of change of the DV is increased according to a function f(x). A dynamic matrix control block uses the dynamically-tuned rate of change of the DV, a current output parameter level, and an output parameter setpoint as inputs to generate a control signal to control a field device that, at least in part, affects the output parameter level.

Claims

1. A method of dynamically tuning control of a steam generating boiler system, comprising:

determining, by an error detector, a presence of an error corresponding to a temperature of output steam, wherein the output steam is generated by the steam generating boiler system for delivery to a turbine, and the determination of the presence of the error is based on a magnitude of a difference between a signal indicative of a measured temperature of the output steam received at the error detector and a signal indicative of a setpoint received at the error detector;

providing, by an output of the error detector to a dynamic matrix controller of a control loop of the steam generating boiler system operating to control the temperature of the output steam, a signal corresponding to the error;

receiving, at the dynamic matrix controller, (i) the signal corresponding to the error provided by the output of the error detector, (ii) a signal indicative of a rate of change of a disturbance variable generated by a device used in a portion of the steam generating boiler system, the portion of the steam generating boiler system excluding any devices included in the control loop, (iii) the signal indicative of the measured temperature of the output steam, and (iv) the signal indicative of the setpoint;

adjusting, by the dynamic matrix controller based on the signal corresponding to the error, the signal indicative of the rate of change of the disturbance variable;

generating, by the dynamic matrix controller, a control signal based on the adjusted signal indicative of the rate of change of the disturbance variable of the portion of the steam generating boiler system; and

controlling, based on the control signal, a manipulated variable of the control loop of the steam generating boiler system to thereby control the temperature of the output steam.

2. The method of claim 1, wherein determining the presence of the error corresponding to the temperature of the output steam comprises detecting a difference between the signal indicative of the setpoint and the signal indicative of the measured temperature of the output steam.

3. The method of claim 1, wherein adjusting the signal indicative of the rate of change of the disturbance variable based on the signal corresponding to the error comprises adjusting the signal indicative of the rate of change of the disturbance variable based on an aggressiveness of tuning determined based on the magnitude of the difference between the signal indicative of the setpoint and the signal indicative of the measured temperature of the output steam.

4. The method of claim 3, wherein adjusting the signal indicative of the rate of change of the disturbance variable based on the aggressiveness of the tuning determined based on the magnitude of the difference between the signal indicative of the setpoint and the signal indicative of the measured temperature of the output steam comprises increasing a magnitude of an adjustment to the signal indicative of the rate of change of the disturbance variable as the magnitude of the difference between the signal indicative of the setpoint and the signal indicative of the measured temperature of the output steam increases.

5. The method of claim 4, wherein adjusting the signal indicative of the rate of change of the disturbance variable based on the aggressiveness of tuning based on the magnitude of the difference between the signal indicative of the setpoint and the signal indicative of the measured temperature of the output steam further comprises decreasing the magnitude of the adjustment to the signal indicative of the rate of change of the disturbance variable as the magnitude of the difference between the signal indicative of the setpoint and the signal indicative of the measured temperature of the output steam decreases.

6. The method of claim 1,

further comprising:

providing the signal indicative of the rate of change of the disturbance variable to a first input of the dynamic matrix controller, and

providing the signal corresponding to the error to a second input of the dynamic matrix controller; and

wherein adjusting the signal indicative of the rate of change of the disturbance variable is performed by the dynamic matrix controller based on the signals received at the first input and at the second input.

7. The method of claim 1,

further comprising providing a signal indicative of a magnitude of the error to an input of a function block, modifying the signal indicative of the magnitude of the error using a function included in the function block, and generating an output of the function block based on the modified signal indicative of the magnitude of the error;

and

wherein adjusting the signal indicative of the rate of change of the disturbance variable based on the signal corresponding to the error comprises adjusting the signal indicative of the rate of change of the disturbance variable based on the output of the function block.

8. The method of claim 7,

further comprising:

providing the signal indicative of the rate of change of the disturbance variable to a first input of the dynamic matrix controller,

providing a signal indicative of the output of the function block to a second input of the dynamic matrix controller; and

wherein adjusting the signal indicative of the rate of change of the disturbance variable based on the output of the function block comprises adjusting, by the dynamic matrix controller, the signal indicative of the rate of change of the disturbance variable based on the signals received at the first input and at the second input of the dynamic matrix controller.

9. The method of claim 1, wherein:

controlling, based on the control signal, the manipulated variable of the control loop of the steam generating boiler system to thereby control the temperature of the output steam comprises providing the control signal to a field device of the control loop of the steam generating boiler system; and

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.

10. The method of claim 1, wherein adjusting the signal indicative of the rate of change of the disturbance variable of the portion of the steam generating boiler system includes adjusting respective values of respective signals indicative of respective rates of change of 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, another manipulated variable of the portion of the steam generating boiler system, or a control variable of the portion of the steam generating boiler system.