Dynamic model of the steam boiler #9 of DMK

Name: ModelKotelDMK Start: January 2007 State: Finished, August 2010 Participants: Roman Savochenko, Maxim Lysenko, Ksenia Yashina Description: The project is targeted to creating a complete dynamic model of a steam boiler № 9 of Dnepr Metallurgical Combine (DMC). Address: Current DB into the SVN-repository, DB in file: dmkkotel9.tlz Live execution: Web-access to the model interface

Contents

Introduction

1 Purpose

2 Development

2.1 Technological process

2.2 Modeling

2.3 Regulation

3 User interface

3.1 Signal object "Start"

3.2 Signal object "Firing"

3.3 Signal object "Flue Gases"

3.4 Signal object "Drainages"

3.5 Signal object "GBF"

3.6 Signal object "GN"

3.7 Signal object "GC"

3.8 Signal object "STEAM"

3.9 Signal object "FW"

3.10 Signal object "Economizer"

3.11 Signal object "AirSup"

4 Results

Links

Introduction

The modelling object of this project for creation the full-scale real time dynamic model is multi-fuel steam boiler №9 of the Dnepr Metallurgical Combine (DMC). The distinctive feature of the boiler is its multi-fuel nature and the following features in optimal control of boiler's loading.

1 Purpose

Functionally, the purpose of the development is creation of the real time model of multi-fuel boiler.

Operational purpose of development is:

• ASC TP control algorithms' testing;
• SCADA-system algorithms' adequate functionality testing;
• Education of the technology staff.

2 Development

In order to speed up the development, use the experience of previous developments, as well as to improve the technology and development tools of the complete dynamic real-time models the decision to build the model in the OpenSCADA environment was made. The OpenSCADA system has the powerful mechanism of user side programming, as well as achievements to create a complete real-time dynamic models, which allow you to quickly create large real-time dynamic models. It was discussed in the paper report (RU) at 5 5 Ukrainian conference of developers and users of free software.

2.1 Technological process

Before the creation the model of the boiler the schematic diagram of the technological process model was formed, based on the schematic diagram of the real process. The scheme is shown in Fig. 1.

2.2 Modeling

For the construction of process model based on the available apparatus' models the original schematic diagram and block calculator (BlockCalc) of the OpenSCADA system were directly used. Apparatus models of the schematic diagram were appended to the block scheme in accordance with the schematic diagram. Part of the blocks were been added to the auxiliary equipment, as well as for the flows' nodes. Nodes' blocks numbers are indicated on the schematic diagram by numbers near the flows' nodes.

The model is made as the two block schemes of the block calculator. Content and properties of block schemes are shown in Table 1.

Table 1. The model's block schemes

ID	Name	Target	Execution period (ms)	Execution time at Athlon 64 3000+ (ms)
kotel9	DMC Boiler9	Contains a model of boiler № 9 Dnepr Metallurgical Combine.	5	1.1
kotel9_cntr	DMC Boiler9 Controller	Contains a model of the boiler's control system.	1000	0.05

From the characteristics of block diagrams you can see that the resource intensity of the overall model to the CPU Athlon 64 3000 + (2000MHz) is 22%.

Table 2 lists the apparatus models being used in accordance with the schematic diagram.

Table 2. The used apparatus models

Apparatus model	Devices (model blocks)
Library "Technological devices (DAQ.JavaLikeCalc.techApp)"
Boiler: barrel (boilerBarrel)	kotel9.Барабан
Boiler: burner (boilerBurner)	kotel9.Топка
Gas compressor (compressor)	kotel9.ДСА, kotel9.ДСБ, kotel9.ДВА, kotel9.ДВБ
Heat exchanger (heatExch)	kotel9.ПП, kotel9.ВП1, kotel9.ВП2, kotel9.СП, kotel9.ЭК1, kotel9.ЭК2
Valve (klap)	kotel9.3ВП, kotel9.5ВП, kotel9.7ВП, kotel9.5ГД9, kotel9.6ГД9, kotel9.7ГД9, kotel9.8ГД9, kotel9.9ГД9, kotel9.10ГД9, kotel9.3ГК9, kotel9.4ГК9, kotel9.6ГК9, kotel9.5ГК9, kotel9.3ГП9, kotel9.4ГП9, kotel9.5ГП9, kotel9.6ГП9, kotel9.4ГПЗ9, kotel9.1Ш9, kotel9.2Ш9, kotel9.11Ш9, kotel9.13Ш9
Network (loading) (net)	kotel9.ParNet, kotel9.Атмосф
Pipe 1->2 (pipe1_2)	kotel9.УЗ3, kotel9.Уз5, kotel9.Уз6, kotel9.Уз7, kotel9.Уз10
Pipe 2->1 (pipe2_1)	kotel9.УЗ1, kotel9.УЗ2, kotel9.УЗ9, kotel9.Уз12
Pipe 3->1 (pipe3_1)	kotel9.Уз8
Source (pressure) (src_press)	kotel9.SrcГД, kotel9.SrcГК, kotel9.SrcВода, kotel9.SrcПГ, kotel9.SrcВоздух
Library "Complex1 functions lib (Special.FLibComplex1)"
PID regulator (pid)	kotel9_cntr.TCA1, kotel9_cntr.F_air_gas, kotel9_cntr.QAC151, kotel9_cntr.LC121, kotel9_cntr.PCA51, kotel9_cntr.FC101, kotel9_cntr.FC102, kotel9_cntr.FC103, kotel9_cntr.FC104, kotel9_cntr.FC105, kotel9_cntr.PSA76
Library "Boiler К9" (DAQ.JavaLikeCalc.k9)
Divider (Delitel)	kotel9_cntr.Air_Gas
Total fuel flow in boiler (Fsum)	kotel9_cntr.Fsum
Inversion (Inversion)	kotel9_cntr.5VP_inv

Through the usage of the apparatus models' library and the dynamic models building conception it was obtained the dynamic model, from which you can get the parameters at any point of the schematic diagram both for the study and for testing the control algorithms.

For information about the technological process the TP parameters were created (Table 3), which provide data from selected nodes of the model.

Table 3. Technological process parameters

Cipher	Description	Properties	Source
DMC Boiler9 (BlockCalc.kotel9)
LC121	The water level in the boiler's drum		Барабан.Lo
LСA122, LSA124	The level of water in a clean drum slot, right	%, (0;100), Precision 0	Барабан.Lo
LSA123	The level of water in a clean drum slot, left	%, (0;100), Precision 0	Барабан.Lo
LCVG121	3FWL-9 position	%, (0;100), Precision 0	3ВП.l_kl1
LCVG122	3FWR-9 position	%, (0;100), Precision 0	3ВП.l_kl2
G_11SH	11G-9 position		11Ш9.l_kl1
G_12SH	12G-9 position		11Ш9.l_kl2
G_13SH	13G-9 position		13Ш9.l_kl1
G_14SH	14G-9 position		13Ш9.l_kl2
P_5VP	5FW(1) position		5ВП.l_kl1
P_5VP_2	5FW(2) position		5ВП.l_kl2
P_7VP	7FW position		7ВП.l_kl1
P_4GP9	4GN9 position		4ГП9.l_kl1
P_5GP9	5GN9 position		5ГП9.l_kl1
P_7GD	7GBF position		7ГД9.l_kl1
P_8GD	8GBF position		8ГД9.l_kl1
FCVG102	5GN-9 position		5ГП9.l_kl1
FCVG103	7GBF9 position		7ГД9.l_kl1
FCVG104	8GN-9 position		8ГД9.l_kl1
FCVG105	4GC-9 position		4ГК9.l_kl1
TCVG1_1	7FW-9 position		7ВП9.l_kl1
TCVG1_2	5FWL-9 position		5ВП9.l_kl1
PCVG76	SEA productivity	rpm, (0;100), Precision 1	ДСА.N
PCVG77	SEB productivity	rpm, (0;100), Precision 1	ДСБ.N
FCV106	BFA productivity	rpm, (0;100), Precision 1	ДВА.N
FCV107	BFB productivity	rpm, (0;100), Precision 1	ДВБ.N
PCA51	Steam pressure after the MSV	at, (0;50), Precision 2	4ГПЗ9.Po
PSA52	Steam pressure in the the boiler's drum	at, (0;40), Precision 2	Барабан.Po1
PCA52	Steam pressure in the boiler's drum	at, (0;50), Precision 2	Барабан.Po1
PSA52_1	Steam pressure in the boiler's drum	at, (0;40), Precision 2	Барабан.Po1
PSA53	GN pressure before the regulating valve	at, (0;40), Precision 2	3ГП9.Po
PSA53_1	GN pressure before the diaphragm	at, (0;40), Precision 2	3ГП9.Po
PSA53_2	GN pressure before the diaphragm	at, (0;40), Precision 2	3ГП9.Po
PSA54	GN pressure after the regulating valve	at, (0;1.5), Precision 3	5ГП9.Po
PA55	GN pressure before the left burner	at, (0;40), Precision 2	6ГП9.Po
PA56	GN pressure before the right burner	at, (0;40), Precision 2	6ГП9.Po
PSA57_1, PSA57_2	GBF pressure on the general pipeline.	at, (0;2), Precision 2	УЗ3.Pi
PSA59	GBF pressure after valve on the left gas pipeline	at, (1;2), Precision 3	10ГД9.Po
PSA60	GBF pressure after valve on the right gas pipeline	at, (1;2), Precision 3	9ГД9.Po
P61	GBF pressure before the left burner	at, (0;1.6), Precision 2	9ГД9.Po
P62	GBF pressure before the right burner	at, (0;1.6), Precision 2	10ГД9.Po
PSA63_1	GC pressure after 5GC-9	at, (0;2), Precision 2	5ГК9.Po
PSA63_2	GC pressure after 3GC-9	at, (0;2), Precision 2	3ГК9.Po
PSA64	GC pressure after the regulating valve	at, (0;2), Precision 3	4ГК9.Po
P65	GC pressure before the left burner	at, (0;1.6), Precision 2	6ГК9.Po
P66	GC pressure before the right burner	at, (0;1.6), Precision 2	6ГК9.Po
P67	The air pressure before the first stage of A/H to the left.	at, (0;1.2), Precision 2	УЗ9.Po
P72	The air pressure in the upper tier of the left burner	at, (0;1.2), Precision 2	УЗ2.Po
P68	The air pressure before the first stage of A/H to the right.	at, (0;1.2), Precision 2	УЗ9.Po
PSA70	Air pressure after the second stage of air-heater	at, (0;1.2), Precision 2	ВП2.Po2
PSA71	Air pressure after the second stage of air-heater	at, (0;1.2), Precision 2	ВП2.Po2
P73, PSA73	The air pressure in the upper tier of the right burner	at, (0;1.16), Precision 2	УЗ2.Po
P74	The air pressure on the lower tier of the left burner	at, (0;1.16), Precision 2	УЗ2.Po
P75, PSA75	The air pressure on the lower tier of the right burner	at, (0;1.16), Precision 2	УЗ2.Po
PCSA76	The vacuum in the fire chamber on the left	at, (0.9;1), Precision 3	Топка.Po
PCSA77	The vacuum in the fire chamber on the right	at, (0.9;1), Precision 3	Топка.Po
P78	The vacuum in front of "SE-A"	at, (0.9;1), Precision 2	1Ш9.Po
P79	The vacuum in front of "SE-B"	at, (0.9;1), Precision 2	2Ш9.Po
PSA80	FW pressure on the left feeding line	at, (0;60), Precision 2	SrcВода.Po
PSA81	FW pressure on the right feeding line	at, (0;60), Precision 2	SrcВода.Po
PSA85	Air pressure after the air heater	at, (0;2), Precision 3	ВП2.Po2
P103	GBF pressure on the diaphragm on the left	at, (0;2), Precision 2	УЗ3.Po2
P104	GBF pressure on the diaphragm on the right	at, (0;2), Precision 2	УЗ3.Po1
Src_GP_Pi	The inlet pressure at the source of GN		SrcПГ.Pi
P_GP_S	GN pressure after the source		SrcПГ.Po
P_GP_4GP	GN pressure after 4GN9		4ГП9.Po
P_3VP_1	3FW9(1) position		3ВП.l_kl1
P_3GP9	3GN9 position		3ГП9.l_kl1
P_6GP9_1	6GN9_1 position		6ГП9.l_kl1
P_6GP9_2	6GN9_2 position		6ГП9.l_kl2
P_5GK	5GC position		5ГК9.l_kl1
Pbar	The pressure in the boiler's drum		Барабан.Po1
TCA1	Steam temperature after MSV		4ГПЗ9.To
F_3VP	Water flow after 3FW		3ВП.Fo
F_5VP	Water flow after 5FW		5ВП.Fo
F_7VP	Water flow after 7FW		7ВП.Fo
Fbar	Water flow into the drum		Барабан.Fi1
F_UZ8	Water flow after UZ8		Уз8.Fo
FC101	Steam flow from boiler	t/h, (0;100), Precision 2	4ГПЗ9.Fo
FC102	Flow of the natural gas after 3GN9		3ГП9.Fo
FC102_0	Natural gas flow after it source		SrcПГ.Fo
FC102_1	Natural gas flow after 4GN9		4ГП9.Fo
FC102_2	Natural gas flow after 5GN9		5ГП9.Fo
FC102_3	Natural gas flow after 6GN9		6ГП9.Fo
FC103	GBF flow on the left gas pipeline		5ГД9.Fi
FC104	GBF flow on the right gas pipeline		6ГД9.Fi
FC105	Flow of coke gas after 5GC9		5ГК9.Fo
FC106	Air flow to the left burner	t/h, (0;100), Precision 1	УЗ2.Fi1
FC107	Air flow to the right burner	t/h, (0;100), Precision 1	УЗ2.Fi2
FA108	The flow of air-superheater on the right feeding line	t/h, (0;200), Precision 2	SrcВода.Fo
F109	Water flow for the thermostat	t/h, (0;200), Precision 2	7ВП.Fo
FA110	The flow of air-superheater on the left feeding line	t/h, (0;200), Precision 2	SrcВода.Fo
QA151	The oxygen content in FG after the superheater	%, (0;20), Precision 2	Топка.O2
QA152	The CO content in FG after the superheater	%, (0;20), Precision 2	Топка.CO
QA153	Oxygen content in the exhaust FG	%, (0;20), Precision 2	Топка.O2
T2	Natural gas temperature	deg.K, (223;323), Precision 2	3ГП9.To
T3	GBF temperature	deg.K, (273;373), Precision 2	5ГД9.Ti
T5	The temperature of the GC before boiler	deg.K, (273;373), Precision 2	4ГК9.To
T7	Air temperature after the second stage of air-heater on the left	deg.K, (273;773), Precision 2	ВП2.To2
T8	Air temperature after the second stage of air-heater on the right	deg.K, (273;773), Precision 2	ВП2.To2
T13	FG temperature before superheater on the left	deg.K, (273;1027), Precision 2	Барабан.To2
T14	FG temperature before superheater on the right	deg.K, (273;1027), Precision 2	Барабан.To2
T15	FG temperature before 2 stage of economizer on the left	deg.K, (273;873), Precision 2	ПП.To1
T16	FG temperature before 2 stage of economizer on the right	deg.K, (273;873), Precision 2	ПП.To1
T17	FG temperature after 2 stage of economizer on the left	deg.K, (273;873), Precision 2	ЭК2.To1
T18	FG temperature after 2 stage of economizer on the right	deg.K, (273;873), Precision 2	ЭК2.To1
T19	FG temperature before the first stage of air-heater on the left	deg.K, (273;873), Precision 2	ЭК1.To1
T20	FG temperature before the first stage of air-heater on the right	deg.K, (273;873), Precision 2	ЭК1.To1
T21	FG temperature before the second stage of air-heater on the left	deg.K, (273;873), Precision 2	ЭК2.To1
T22	FG temperature before the second stage of air-heater on the right	deg.K, (273;873), Precision 2	ЭК2.To1
T23	FG temperature before 1 stage of economizer on the left	deg.K, (273;873), Precision 2	ВП2.To1
T24	FG temperature before 1 stage of economizer on the right	deg.K, (273;873), Precision 2	ВП2.To1
TA25	FG temperature before th "SE-A"	deg.K, (273;673), Precision 2	1Ш9.To
TA26	FG temperature before th "SE-B"	deg.K, (273;673), Precision 2	2Ш9.To
T35	The temperature of water on the left feeding line	deg.K, (273;473), Precision 2	3ВП.To
T36	The temperature of water on the right feeding line	deg.K, (273;473), Precision 2	3ВП.To
T37	The water temperature after the economizer on the left	deg.K, (273;673), Precision 2	ЭК2.To2
T38	The water temperature after the economizer on the right	deg.K, (273;673), Precision 2	ЭК2.To2
DMC Boiler9 Controller (BlockCalc.kotel9_cntr)
TCA1	Steam temperature at the outlet	K, (273;800), Precision 0	TCA1.*
QAC151	The percentage of oxygen in the flue gases.	%, (0;15), Precision 1	QAC151.*
LC121	Level in the boiler's drum	%, (0;100), Precision 1	LC121.*
5VP		%, (0;100), Precision 1	5VP_inv.OVar
FC101	Steam flow from the boiler	t/h, (0;150), Precision 0	FC101.*
FC102	Natural gas flow	t/h, (0;6), Precision 1	FC102.*
FC103	Flow of blast furnace gas on the left gas pipeline	t/h, (0;70), Precision 1	FC103.*
FC104	Flow of blast furnace gas on the right gas pipeline	t/h, (0;70), Precision 1	FC104.*
FC105	Flow of the coke oven gas	t/h, (0;10), Precision 1	FC105.*
PSA76	The vacuum in the fire chamber	at, (0.9;1), Precision 3	PSA76.*

2.3 Regulation

The dynamic model itself may be unstable without control. For example, the drum level parameter does not have the self-regulation and goes to extremes in the case of the balance absence in the control parameters. Because of this reason, as well as to create the self-sustaining model, that can operate autonomously and without the PLC as a controller, the regulators controller's object was created for the boiler's model according to the regulation schemes in Fig. 2 - 4.

3 User interface

The model's user interface contains eleven signal objects (Fig. 5). Each object contains several mnemo, graphics group, contour group and overviews group.

3.1 Signal object "Start"

3.2 Signal object "Firing"

3.3 Signal object "Flue Gases"

3.4 Signal object "Drainages"

3.5 Signal object "GBF"

3.6 Signal object "GN"

3.7 Signal object "GC"

3.8 Signal object "STEAM"

3.9 Signal object "FW"

3.10 Signal object "Economizer"

3.11 Signal object "AirSup"

4 Results

The development result is complete dynamic model of the technological process of the multifuel steam boiler for the high pressure and high productivity. This model is available in three languages ​​and is included to the OpenSCADA distributives to demonstrate the functions and features.

The model provides the availability to control of TP on behalf of the operator including the following operations:

• regulators control:
  • regulator's mode change: "Automate", "Manual" and "Cascade";
  • set of the desirable setpoint value or manual output of the executive mechanism;
  • PID-regulator's parameters configuration.

In general, the following regulators take a full part at the control scheme :

• LC121 — level in the boiler's drum;
• PSA76 — the vacuum in the boiler furnace;
• FC101 — steam flow from the boiler;
• FC102 — natural gas flow;
• FC103, FC104 — flow of blast furnace gas on the left gas pipeline ;
• FC105 — flow of the coke oven gas;
• QAC151 — the percentage of oxygen in the flue gases;
• TCA1 — steam temperature at the outlet.

In an applied sense the model let us to work out the control algorithms of the multi fuel supply.

Resource consumption of the model is 70% for the CPU 800 MHz, x86 architecture.

Links

Referring pages:

HomePageEn/Server
HomePageEn/Using/ModelDMKK9