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Dynamic model of steam boiler DMK

Name: ModelKotelDMK
Founded: January 2007
Version: 1.0.0
State: Finished, August 2010
Participants: Lysenko Maxim, Savochenko Roman, Yashina Ksenia
Description: The project targets for creation full dynamic model steam boiler #9 Dnepr Metallurgical Combine (DMC).
Address: DB in file: dmkkotel9.tlz
Boiler (50 Kb)


Contents

Introduction

The modelling object for the project, for creation full-scale dynamic model of real time, is multi-fuel steam boiler Dnepr Metallurgical Cobine (DMC) #9. A distinctive feature of the boiler is his multi-fuel nature and by that follow features in optimal control for boiler loading.

1 Targeting

Functionality, the development targeted for creation the real time model of multi-fuel boiler DMC.


Exploitation target the development is:

2 Development

With targets acceleration, using early developments experience, and also for perfecting the technologies and tools for creation full dynamic models real time decided the model build into open SCADA system OpenSCADA environment. System OpenSCADA has mostly powerful mechanism for user side programming, and also has achievements for creation full dynamic real time models, which allow fast creation big dynamic models real time. Detailed about this has been discussed in PDF Documentreport (RU), at 5 Ukrainian conference of developers and users free software.

2.1 Technological process

Before the Boiler model creation has been forming schematic diagram of the technological process, based on schematic diagram real technological process. Obtained diagram painted at Fig.1.


The boiler DMK #9 technological scheme. (141 Kb)
Fig. 1. The boiler DMK #9 technological scheme.

2.2 Modeling

For the technological process model forming based on allowed apparatus models has been direct used source schematic diagram and block calculator (BlockCalc) of system OpenSCADA. The apparatus models of the schematic diagram was appending to block scheme in accordance with the schematic diagram. Part new blocks has been added for auxiliary devices, and also flow's nodes. Node's block numbers set on schematic diagram by numbers about the flow's nodes.


The model made in view two block schemes by block calculator. Content and properties of the block schemes allowed into 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 Contained Boiler #9 model of Dnepr Metallurgical Combine. 5 1.1
kotel9_cntr DMC Boiler9 Controller Contained control system Boiler #9 model of Dnepr Metallurgical Combine. 1000 0.05

From the block schemes properties you can see, resource intensity at whole to central processor Athlon 64 3000+ (2000МГц) is 22%.


In table 2 allow used apparatus models list in accordance with schematic diagram.


Table 2. 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 library apparatus models and the dynamic models build conception has been obtained the dynamic model, from that can get parameters into any point the schematic diagram both for the study and control algorithms for testing.


For getting the information about the technological process has been created TP parameters (table 3), which allow data from selected model's nodes.


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

By itself, the dynamic model may be unstable without control. For example, drum level parameter have not self-regulation and gone to edge points at case balance miss into regulation parameters. By that reason and for create all-sufficient model, which capable for work autonomous and without PLC for regulation, has been created regulators controller object for the boiler model in accordance with regulation schemes on figures 2 - 4.


Level and steam temperature regulation. (46 Kb)
Fig. 2. Level and steam temperature regulation.

Rarefaction into the chamber regulation. (48 Kb)
Fig. 3. Rarefaction into the chamber regulation.

Steam and Gas flows regulation. (86 Kb)
Fig. 4. Steam and Gas flows regulation.

3 User interface

The model user interface contain elven signal objects (Fig.5). Each signal object contain several mnemo, graphics group, contour group and overviews group.


User's interface generic view window. (133 Kb)
Fig. 5. User's interface generic view window.

3.1 Signal object "Start"

Signal object "Start" mnemo. (90 Kb)
Fig. 6. Signal object "Start" mnemo.

Signal object "Start" graphics group. (25 Kb)
Fig. 7. Signal object "Start" graphics group.

Signal object "Start" contours group. (38 Kb)
Fig. 8. Signal object "Start" contours group.

Signal object "Start" overview group. (15 Kb)
Fig. 9. Signal object "Start" overview group.

3.2 Signal object "Firing"

Signal object "Firing" mnemo. (88 Kb)
Fig. 10. Signal object "Firing" mnemo.

Signal object "Firing" graphics group. (26 Kb)
Fig. 11. Signal object "Firing" graphics group.

Signal object "Firing" contour group. (37 Kb)
Fig. 12. Signal object "Firing" contour group.

Signal object "Firing" overview group. (15 Kb)
Fig. 13. Signal object "Firing" overview group.

3.3 Signal object "Flue Gases"

Signal object "Flue Gases" mnemo. (63 Kb)
Fig. 14. Signal object "Flue Gases" mnemo.

Signal object "Flue Gases" mnemo 2. (31 Kb)
Fig. 15. Signal object "Flue Gases" mnemo 2.

Signal object "Flue Gases" graphics group. (26 Kb)
Fig. 16. Signal object "Flue Gases" graphics group.

Signal object "Flue Gases" contour group. (31 Kb)
Fig. 17. Signal object "Flue Gases" contour group.

Signal object "Flue Gases" overview group. (19 Kb)
Fig. 18. Signal object "Flue Gases" overview group.

3.4 Signal object "Drainages"

Signal object "Drainages" mnemo. (74 Kb)
Fig. 19. Signal object "Drainages" mnemo.

Signal object "Drainages" graphics group. (18 Kb)
Fig. 20. Signal object "Drainages" graphics group.

file:dr_gcont.png
Fig. 21. Signal object "Drainages" contour group.

Signal object "Drainages" overview group. (14 Kb)
Fig. 22. Signal object "Drainages" overview group.

3.5 Signal object "GBF"

Signal object "GBF" mnemo. (57 Kb)
Fig. 23. Signal object "GBF" mnemo.

Signal object "GBF" graphics group. (23 Kb)
Fig. 24. Signal object "GBF" graphics group.

Signal object "Drainages" contour group. (20 Kb)
Fig. 25. Signal object "GBF" contour group.

Signal object "GBF" overview group. (14 Kb)
Fig. 26. Signal object "GBF" overview group.

3.6 Signal object "GN"

Signal object "GN" mnemo. (50 Kb)
Fig. 27. Signal object "GN" mnemo.

Signal object "GN" graphics group. (24 Kb)
Fig. 28. Signal object "GN" graphics group.

Signal object "GN" contour group. (18 Kb)
Fig. 29. Signal object "GN" contour group.

Signal object "GN" overview group. (13 Kb)
Fig. 30. Signal object "GN" overview group.

3.7 Signal object "GC"

Signal object "GC" mnemo. (53 Kb)
Fig. 31. Signal object "GC" mnemo.

Signal object "GC" graphics group. (22 Kb)
Fig. 32. Signal object "GC" graphics group.

Signal object "GC" contour group. (19 Kb)
Fig. 33. Signal object "GC" contour group.

Signal object "GC" overview group. (12 Kb)
Fig. 34. Signal object "GC" overview group.

3.8 Signal object "STEAM"

Signal object "STEAM" mnemo. (50 Kb)
Fig. 35. Signal object "STEAM" mnemo.

Signal object "STEAM" graphics group. (23 Kb)
Fig. 36. Signal object "STEAM" graphics group.

Signal object "STEAM" contour group. (27 Kb)
Fig. 37. Signal object "STEAM" contour group.

Signal object "STEAM" overview group. (12 Kb)
Fig. 38. Signal object "STEAM" overview group.

3.9 Signal object "FW"

Signal object "FW" mnemo. (67 Kb)
Fig. 39. Signal object "FW" mnemo.

Signal object "FW" graphics group. (27 Kb)
Fig. 40. Signal object "FW" graphics group.

Signal object "FW" contour group. (22 Kb)
Fig. 41. Signal object "FW" contour group.

Signal object "FW" overview group. (16 Kb)
Fig. 42. Signal object "FW" overview group.

3.10 Signal object "Economizer"

Signal object "Economizer" mnemo. (75 Kb)
Fig. 43. Signal object "Economizer" mnemo.

Signal object "Economizer" graphics group. (26 Kb)
Fig. 44. Signal object "Economizer" graphics group.

Signal object "Economizer" contour group. (30 Kb)
Fig. 45. Signal object "Economizer" contour group.

Signal object "Economizer" overview group. (15 Kb)
Fig. 46. Signal object "Economizer" overview group.

3.11 Signal object "AirSup"

Signal object "AirSup" mnemo. (65 Kb)
Fig. 47. Signal object "AirSup" mnemo.

Signal object "AirSup" mnemo 2. (53 Kb)
Fig. 48. Signal object "AirSup" mnemo 2.

Signal object "AirSup" graphics group. (27 Kb)
Fig. 49. Signal object "AirSup" graphics group.

Signal object "AirSup" contour group. (31 Kb)
Fig. 50. Signal object "AirSup" contour group.

Signal object "AirSup" overview group. (15 Kb)
Fig. 51. Signal object "AirSup" overview group.

4 Results

Translation is going now
Результатом разработки стала полноценная динамическая модель технологического процесса многотопливного парового котла на высокое давление и большую производительность. Данная модель доступна на трёх языках и включена в дистрибутивы системы OpenSCADA для демонстрации функций и возможностей.


Модель предусматривает возможность управления ТП от лица оператора, включая операции:


В целом, в схеме управления, полноценно участвуют следующие регуляторы:


В прикладном смысле модель позволила отработать алгоритмы управления подачей нескольких родов топлива.


Ресурсоёмкость модели составила 70% на ядре процессора 800 МГц, архитектуры x86.

Links

Referring pages: HomePageEn/Server
HomePageEn/Using/ModelDMKK9


 
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