Spray Control at TPP
Spray Control at TPP
Complexity
Volume 2019, Article ID 9361723, 12 pages
https://doi.org/10.1155/2019/9361723
Research Article
Performance Analysis of Reheat Steam Temperature
Control System of Thermal Power Unit Based on Constrained
Predictive Control
Xiaoli Li ,1,2,3 Jian Liu ,1 Kang Wang ,1 Fuqiang Wang,4 and Yang Li5
1
Faculty of Information Technology, Beijing University of Technology, Beijing 100124, China
2
Beijing Key Laboratory of Computational Intelligence and Intelligent System, Engineering Research Center of Digital Community,
Ministry of Education, Beijing 100124, China
3
Beijing Advanced Innovation Center for Future Internet Technology, Beijing University of Technology, Beijing 100124, China
4
Technology Research Center, Shenhua Guohua Electric Power Research Institute Corporation, Beijing 100025, China
5
School of International Studies, Communication University of China, Beijing 100024, China
Received 17 April 2019; Revised 28 June 2019; Accepted 8 July 2019; Published 5 August 2019
Copyright © 2019 Xiaoli Li et al. This is an open access article distributed under the Creative Commons Attribution License, which
permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
The reheat steam temperature control system of thermal power unit is a complex control object with time-varying parameters
and large delay. In order to achieve precise control of reheat steam temperature, the performance of the reheat temperature control
system is analyzed according to the data that are obtained based on the constrained predictive control algorithm. Firstly, the process
and mathematical model of reheat steam temperature control system are introduced. Then the principle of constrained predictive
control algorithm is analyzed. Finally, the steady-state values of control quantities of reheat steam temperature control system under
different conditions are given by MATLAB simulation, and, by analyzing the steady-state values and steady-state time of the input
and output of the system, the reference values and the regulating law of the control quantities and the specific constraint range of
the control quantities of the system are given, which can provide reference data and theoretical basis for the field adjustment of the
reheat steam temperature control system in power plant and improve the safety and effectiveness of the system.
that the service life of unit may be reduced. If the steam (MPSO-RBF) for radial basis function (RBF) neural network
temperature is too low, the humidity of steam will be very based on modified particle swarm optimization (MPSO)
high, which not only makes the last turbine blades more is presented in [8]. The results have proved that MPSO-
vulnerable to damage, but also reduces the thermal efficiency RBF method has good performance index. In [9], a scheme
of unit. The large variation of reheat steam temperature combining neural network identification technology and
will also cause unit fatigue and reduce the service life of adaptive inverse control technology is proposed for the
unit. Therefore, understanding the regulating law of the control of boiler superheated steam temperature in fossil-
control quantities and the constraint range of the control fired power plant. The identified inverse model is preset
quantities of the reheat steam temperature control system can as the controller and connected in series with the con-
not only ensure the safety of thermal equipment, but also trolled object to form an adaptive inverse control system.
have important significance to the stability of reheat steam In [10, 11], active disturbance rejection control (ADRC) is
temperature. applied in the control of superheated steam temperature.
In order to improve the control effect of steam temper- Comparing with PID algorithm, the method achieved an
ature, a large number of scholars have adopted a variety excellent performance. In [12], a nonlinear control strategy
of advanced control strategies to study it. A new cascade for steam power plants is proposed. The strategy decomposes
feedback control system with load feed-forward of reheat the overall plant into three separate subsystems and applies
steam temperature is proposed in [1]. Single-Neuron Self- decoupling with dead time compensation for each one of
adaptive PSD algorithm controller applied to outer loop and them. The simulation results show that the method has
double-degree PID controller is applied to inner loop, which good performance and robustness. When the superheated
achieves good control effect. In [2], based on the charac- steam temperature is controlled by adjusting the cooling
teristics of superheated steam temperature of a boiler, a water, the nonlinear characteristics of the valve are caused
new cascade control system is designed. The main regulator by the flow rate. In [13], by collecting the valve input and
adopts multimodel observer control, and the secondary output data and fitting the valve flow characteristic curve, a
controller adopts weighted synthesizing proportional control. valve opening degree compensator based on the polynomial
The system integrates the characteristics of the multimodel fitting method was designed. The simulation results show
control with those of the state variable control with observer. that the method can overcome the nonlinear problem caused
The results show that the control system has strong robust- by valve flow characteristics. In [14], a system of automatic
ness. In [3], an adaptive predictive control algorithm is control over the temperature of superheated steam for the
designed for the reference model, and two compensators boiler with three-tier steam cooling system is considered.
are introduced; one is two-order compensator for process; A regulating algorithm rests on a cascade control method
the other one is time delay compensator for the reference with the temperature error correction based on a force signal.
model. The algorithm has been applied in a 200MW peak The force signal is a speed of steam temperature change
regulating drum boiler for reheating temperature process, after the condensate injection. The simulation results show
and high control accuracy is obtained. As the superheated the effectiveness of the method. Besides, based on robust
steam temperature has large inertia, time-delay, and non- H∞ control method, the reheat steam temperature control
linearity and its dynamic characteristics change with the system of boiler is studied in [15]. In [16], according to the
operating conditions, a self-tuning PID controller based on characteristics of reheat steam temperature, a hybrid opti-
fuzzy-RBF neural networks is presented for its control in mization method based on Biogeography-Based Optimiza-
[4], which has the advantages of traditional PID control, tion (BBO) algorithm is proposed to optimize the traditional
neutral networks control, and fuzzy control and optimizes PID controller. It turns out that the optimized PID controller
online PID parameters. In [5], a new intelligent control has better tracking ability and better anti-internal and exter-
algorithm of cloud models is proposed. The variant dimen- nal interference performance in reheat steam control sys-
sion cloud model intelligent controller, which contains a tem.
one-dimension cloud model controller to eliminate steady- Aiming at the difficulty of reheat steam temperature
state error, is designed, and it is used for superheated steam control, model predictive control is a useful control method.
temperature control of a supercritical once-through 600MW It can deal with multivariable, constrained, and time-delay
boiler. In [6], a multimodel internal mode control strategy problems effectively and has good dynamic control per-
is proposed, and it has been successfully applied to a 1024 formance. Model predictive control (MPC) [17–20] was
t/h supercritical pressure boiler. Performance studies show proposed in the 1980s. It has been improved and developed
that the control strategy ensures that the superheated steam continuously in recent years and has been widely used in
temperature stays within the desired range for both steady many industrial fields such as robots [21–24]. The control
and varying loads. In [7], dynamic matrix control (DMC) mechanism of MPC is that, at each sampling time, according
is applied in controlling steam temperatures of a large-scale to the current measurement information, an open-loop
once-through boiler-turbine system. Online optimization is optimization problem in finite time domain is solved online,
performed for the DMC using the step response model. The and the first element of the control sequence is acted on
simulation results show satisfactory performance of the pro- the controlled object. At the next sampling time, the above
posed DMC technique. Aiming at the characteristics of large process is repeated; that is, the optimization problem is
inertia, large time delay, and nonlinearity of Reheater Tem- refreshed and resolved with new measurements. In addition,
perature Control System, a hybrid optimization algorithm in the actual industrial control process, the physical quantity
Complexity 3
Sprinkler of
side A (u3)
Steam from High
Pressure Cylinder Sprinkler of
side B (u4)
Pumping water
Overfire Flue
air Burnout gas
zone Super-
Reburning Reheater
heater
fuel Reburning
zone Econo- Econo-
u1 mizer mizer
Flue damper Flue damper
Primary
combustion
zone
u2
Air Powdered-
coal Mixture
of the system can only be taken in a certain range, such 2. The Technological Principle and
that the opening range of the valve dampers in the unit of Mathematical Model of Reheat Steam
thermal power plant can only be taken from 0% to 100%. Temperature Control System
Executing agencies are not allowed to change too much to
prevent damage to them. Therefore, in actual control process, 2.1. The Technological Principle of Reheat Steam Temperature
the control input and output must be constrained according Control System. At present, in order to improve the opera-
to the actual requirement, so that their values can be kept tion efficiency of large-scale thermal power unit, the steam
within a certain range. Considering the above factors, the which has finished the work in the high-pressure cylinder is
reheat steam temperature control system of 660 MW Ultra- reheated generally. The process of steam reheating involves
supercritical Once-through Boiler in a power plant is taken three steps. At first, the steam discharged from high pressure
as the research object in this paper. And the control process cylinder is resent back to the boiler for heating. Then the
of reheat steam temperature in coal-fired power plant is reheat steam is heated to a certain temperature. Finally, the
studied and analyzed by using constrained predictive control reheat steam is sent to the middle- and low-pressure cylinders
algorithm. Through the simulation results, the regulation law for work.
and the restriction range of system inputs during the reheat There are many ways to regulate reheat steam tempera-
steam temperature system regulation are obtained, which ture. The commonly used methods include adjusting flue gas
provides theoretical and data support for field regulation. In damper opening, swinging burner swing angle, and spraying
this way, we can improve the safety and efficiency of reheat water to reduce temperature. The process diagram of reheat
steam temperature control and the quality of reheat steam steam temperature control system is shown in Figure 1. In
temperature control of ultra-supercritical coal-fired units. the control process of steam temperature, reheat steam pipe
The paper is organized as follows. In Section 2, the tech- is generally divided into side A and side B. The burner and
nological principle and mathematical model of reheat steam the flue gas baffle act on the reheat steam temperature of
temperature control system are formulated. Then the prin- both sides at the same time. The sprinkler that is installed
ciple of constrained predictive control algorithm is analyzed on the A side and the B side of the reheater can only control
in Section 3. In Section 4, we apply constrained predictive the reheat steam temperature of the A side and the B side,
control to reheat steam temperature control system and carry respectively. When reheat steam temperature is controlled
out MATLAB simulation. And, by analyzing the simulation by flue gas damper, the tail flue of the boiler is divided into
results, the input regulation law and appropriate constraint two parallel flues. Low temperature reheater is arranged in
range of system inputs are given. Finally, conclusions are the main flue, low temperature superheater is arranged in
given in Section 5. the bypass flue, and economizer is arranged behind them.
4 Complexity
Temperature regulating damper is installed under econo- steam temperature on the A side of reheater, rather than the
mizer. By changing the opening of two flue dampers, the ratio actual reheat steam temperature. If the initial temperature of
of flue gas that flows through cryogenic reheater and cryo- reheat steam is 580∘ C and the expected temperature is 590∘C,
genic superheater is changed, so as to control the temperature then 𝑦1 is the change of the initial temperature, that is, 10∘ C.
of reheat steam. Specifically, when the opening of the flue Similarly, 𝑦2 is the variance of reheat steam temperature on
gas damper increases, the reheat steam temperature increases; the B side of reheater, 𝑢1 is the variance of the flue gas damper
otherwise the reheat steam temperature decreases. The way of opening, 𝑢2 is the variance of the burner swing angle, 𝑢3 is
adjusting the swing angle of the burner is to change the up and the variance of the sprinkler valve opening on the A side of
down inclination angle of the swing burner nozzle, which will reheater, and 𝑢4 is the variance of the sprinkler valve opening
adjust the position of the high temperature flame center in the on the B side of reheater.
furnace, so as to change the flue gas temperature at the outlet The transfer functions of burner swing angle-reheat steam
of the furnace and control the reheat steam temperature. temperature, flue gas damper-reheat steam temperature,
Similar to the flue gas damper, the reheat steam temperature and spray desuperheating-reheat steam temperature can be
increases with the increase of burner swing angle; otherwise described by the mode of first-order inertia plus pure delay.
the reheat steam temperature decreases. In case of emergency, The expression of the transfer functions is as follows:
sprinklers on both sides of reheater can spray water to cool
down. 𝐾
In general, adjusting flue gas damper opening and burner 𝐺 (𝑠) = exp (−𝜏𝑠) , (2)
𝑇𝑠 + 1
swing angle is the main control means in the control process
of reheat steam temperature system. The performance of
burner swing angle regulation and flue gas damper regulation where 𝐾 is the gain, 𝑇 is the first-order inertia time, and
is stable, and heat shock is small, so the two control methods 𝜏 is the delay time. The transfer function form of 𝐺11 , 𝐺12 ,
have higher thermal economy. Although spray desuperheat- 𝐺13 , 𝐺21 , 𝐺22 , 𝐺24 in model (1) is determined by (2).
ing has a rapid effect on reheat steam temperature control,
it will reduce the thermal efficiency of the unit, so it is not 3. Theoretical Analysis of Constrained
the main method of regulation. Usually only in the process of
Predictive Control [26]
unit start-up and shutdown, or in the case of accident, spray
desuperheating is used as an auxiliary emergency means. The theoretical analysis of predictive control algorithm is
Besides, in the normal operation of the unit, small amount usually based on the state space equation of the system model.
of cooling water can be used intermittently, or it can be Therefore, the transfer function model of the research object
combined with other temperature regulation methods as a in this paper needs to be transformed into the state space
fine-tuning method of reheat steam. model. The transformation method can be easily found in
many data [27], so it is no longer detailed.
2.2. The Mathematical Model of Reheat Steam Temperature The state space incremental model of the linear discrete
Control System. From the above analysis, we can learn that time system is considered as follows:
the ideal control method for the reheat steam temperature
should be to use the burner swing angle and the flue gas
damper to adjust the reheat steam temperature roughly and Δ𝑥 (𝑘 + 1) = 𝐴Δ𝑥 + 𝐵𝑢 Δ𝑢 (𝑘) + 𝐵𝑑 Δ𝑑 (𝑘) , (3a)
use the method of water spraying to reduce the temperature
𝑦𝑐 (𝑘) = 𝐶𝑐 Δ𝑥 (𝑘) + 𝑦𝑐 (𝑘 − 1) , (3b)
to achieve fine adjustment. As an emergency safety measure,
the sprinkler valve should be kept as small as possible. At the 𝑦𝑏 (𝑘) = 𝐶𝑏 Δ𝑥 (𝑘) + 𝑦𝑏 (𝑘 − 1) , (3c)
same time, the variance of burner swing angle and flue gas
damper opening must be limited to a certain range.
According to the requirements of reheat temperature where
control process, the mathematical model [25] of reheat steam
temperature control system for 660 MW ultra-supercritical Δ𝑥 (𝑘) = 𝑥 (𝑘) − 𝑥 (𝑘 − 1) ,
once-through boiler in a power plant is established:
Δ𝑢 (𝑘) = 𝑢 (𝑘) − 𝑢 (𝑘 − 1) , (4)
𝑢1
[ ] Δ𝑑 (𝑘) = 𝑑 (𝑘) − 𝑑 (𝑘 − 1) .
𝑦1 𝐺11 𝐺12 𝐺13 0 [𝑢2 ]
[ ]=[ ]×[ ]
[𝑢 ] . (1)
𝑦2 𝐺21 𝐺22 0 𝐺24 [ 3] In the model ((3a), (3b), and (3c)), Δ𝑥(𝑘) ∈ R𝑛𝑥 is the
[𝑢4 ] state increment; Δ𝑢(𝑘) ∈ R𝑛𝑢 is the increment of control
input; Δ𝑑(𝑘) ∈ R𝑛𝑑 is the increment of measurable external
where 𝑢1 , 𝑢2 , 𝑢3 , 𝑢4 are the control quantities of the system interference; 𝑦𝑐 (𝑘) ∈ R𝑛𝑐 is the controlled output; 𝑦𝑏 (𝑘) ∈
and 𝑦1 , 𝑦2 are the output of the system. It should be noted R𝑛𝑏 is the constrained output; 𝐴, 𝐵𝑢 , 𝐵𝑑 , 𝐶𝑐 , 𝐶𝑏 is the system
that the model is established based on the input variance and matrix of the corresponding dimension.
output variance of reheat steam temperature control system. The control objective is to make the controlled output 𝑦𝑐
For example, in model (1), 𝑦1 is the variance of the reheat track the given reference input 𝑟. At the same time, the control
Complexity 5
quantity, control increment, and output of the system satisfy 𝑅(𝑘 + 1) is a reference sequence of control output, and it is
the following control constraints and output constraints: given as
where 𝐶𝑐 𝐴
[ ]
[𝐶𝑐 𝐴2 + 𝐶𝑐 𝐴]
2 [ ]
𝐽 (𝑥 (𝑘) , Δ𝑈 (𝑘)) = Γ𝑦 (𝑌𝑝,𝑐 (𝑘 + 1 | 𝑘) − 𝑅 (𝑘 + 1)) [
..
]
𝑆𝑥 = [
[
] ,
]
(9) [ . ]
2 [ 𝑝 ]
+ Γ𝑢 Δ𝑈 (𝑘) . [ ]
∑ 𝐶𝑐 𝐴𝑖
[ 𝑖=1 ]𝑝×1
In the above optimization problems, Γ𝑦 and Γ𝑢 are weighted
matrices, and they are given as follows: 𝐼𝑛𝑐 ×𝑛𝑐
[ ]
[𝐼𝑛 ×𝑛 ]
[ 𝑐 𝑐]
Γ𝑦 = diag {Γ𝑦,1 , Γ𝑦,2 , ⋅ ⋅ ⋅ Γ𝑦,𝑝 }𝑝×𝑝 , 𝐼=[
[ .. ]
] ,
[ . ]
(10) [ ]
Γ𝑢 = diag {Γ𝑢,1 , Γ𝑢,2 , ⋅ ⋅ ⋅ Γ𝑢,𝑚 }𝑚×𝑚 , [𝐼𝑛𝑐 ×𝑛𝑐 ]𝑝×1
6 Complexity
Table 3: The model of spray desuperheating-reheat steam temperature under 400 MW, 500 MW, and 600 MW.
analyzed. From the Tables 4–7, it can be seen that when Δ𝑢𝑗 is
equal and the constraint of control quantities is invariable, the
586 three steady-state values of 𝑢1 do not change much under the
three loads. That is to say, when the reheat steam temperature
584 rises from 580∘ C to 590∘ C and the load of generator unit is
400MW, the variance of flue gas damper opening is basically
582 the same as that under 500MW and 600MW load. Besides,
the smaller the constraint range of 𝑢1 is, the closer the three
steady-state values of 𝑢1 are under the three loads. Thus,
580
0 100 200 300 400 500 600 although the model parameters of reheat steam temperature
Time (10s) control system change with the change of generator load, the
y1
y2 adjustment of flue gas damper opening just has little change
under different loads. Taking Table 7 as an example, when
Figure 2: The variation curve of reheat steam temperature when the 𝑢𝑗 ∈ [0, 8] and Δ𝑢𝑗 = 0.5, the three steady-state values of
load of generator unit is 400MW, 𝑢𝑗 ∈ [0, 15], Δ𝑢𝑗 = 0.5. 𝑢1 , which are 7.57, 7.91, and 7.67, respectively, are the closest
under the three loads. The variation range of 𝑢1 is between
7.57 and 7.91, and the change is not obvious. Therefore, under
16 any other load, the control quantity 𝑢1 can take the value from
14 7.57 to 7.91.
Next, we analyze the change of 𝑢2 according to the
12 Tables 4–7. It can be seen that when the Δ𝑢𝑗 is equal and
10 the constraint of control quantities is invariable, 𝑢2 changes
greatly under the three loads. And the higher the generators’
8 load is, the smaller the 𝑢2 is. Taking Table 5 as an example,
ui
16 16
14 14
12 12
Temperature (∘ C)
Temperature (∘ C)
10 10
8 8
6 6
4 4
2
2
0
0
−2
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 −2
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Time (s)
Time (s)
Figure 4: The variation curve of 𝑦1 when the load of generator unit
is 400MW, 𝑢𝑗 ∈ [0, 12], and the increment of 𝑢2 is 4. Figure 6: The variation curve of 𝑦1 when the load of generator unit
is 600MW, 𝑢𝑗 ∈ [0, 12], and the increment of 𝑢2 is 4.
15 589
588
587
Temperature (∘ C)
10 586
Temperature (∘ C)
585
584
5
583
582
0 581
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Time (s) 580
0 100 200 300 400 500 600
Time (10s)
Figure 5: The variation curve of 𝑦1 when the load of generator unit
is 500MW, 𝑢𝑗 ∈ [0, 12], and the increment of 𝑢2 is 4. y1
y2
7 8
6 7
6
5
5
4
4
ui
3
ui
3
2
2
1
1
0 0
−1 −1
0 100 200 300 400 500 600 0 100 200 300 400 500 600
Time (10s) Time (10s)
u1 u3 u1 u3
u2 u4 u2 u4
Figure 8: The variation curve of system input when the load of Figure 10: The variation curve of system input, when the load of
generator unit is 400MW, 𝑢𝑗 ∈ [0, 6], Δ𝑢𝑗 = 0.5. generator unit is 400MW, 𝑢𝑗 ∈ [0, 7.5], Δ𝑢𝑗 = 0.5.
592
values of 𝑢3 , 𝑢4 are 0.03 and 0, respectively, which have almost
590 reached the lower bound of input constraint range. As can be
seen from Figure 9, the steady-state values of 𝑦1 , 𝑦2 are 590
and 589.9, respectively, which reach the desired temperature
588
Temperature (∘ C)
592 learn that, with the increase of the load of the generator
unit, the adjusting range of burner swing angles should
590 be gradually reduced, and large adjustment of the control
quantities may cause reheat steam temperature being too
588 high and the equipment is damaged, which means that,
Temperature (∘ C)
Figure 11: The variation curve of reheat steam temperature when the
5. Conclusions
load of generator unit is 400MW, 𝑢𝑗 ∈ [0, 40], Δ𝑢𝑗 = 2. Aiming at the problem of reheat steam temperature control,
the reheat steam temperature control system of 660MW
thermal power generator unit is studied based on the con-
40
strained predictive control algorithm in this paper. Under the
35 condition of input constraint, steady state value of control
quantities and the time that system reaches steady state in
30 different constraint ranges are listed in tabular form. By
analyzing the data in the tables, the reference values of
25
system input and input constraint are given. These data and
20 analysis provide reference for field adjustment of reheat steam
ui
10 Data Availability
5 The experimental data used to support the findings of this
study are included within the article.
0
0 100 200 300 400 500 600
Time (10s)
Conflicts of Interest
u1 u3
u2 u4 The authors declare that there are no conflicts of interest
Figure 12: The variation curve of system input when the load of
regarding the publication of this paper.
generator unit is 400MW, 𝑢𝑗 ∈ [0, 40],Δ𝑢𝑗 = 2.
Acknowledgments
This work is supported in part by the National Natu-
the largest fluctuation. Therefore, in the existing data, we can ral Science Foundation of China under Grants 61873006,
roughly consider that the maximum upper bound value of the 61473034, and 61673053 and in part by the National Key
constraint range of the control quantities is 15. Research and Development Projects 2018YFC1602704 and
From the analysis of Section 4.3 of the control quan- 2018YFB1702704 and Beijing Major Science and Technology
tities of reheat steam temperature control system, we can Special Projects under Grant No. Z181100003118012.
12 Complexity
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