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

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 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:

• ASC TP control algorithms testing;
• SCADA-system adequate algorithm functionality testing;
• Technological personal training.

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 report (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.

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+ (2000MHz) 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.Áàðàáàí
Boiler: burner (boilerBurner)	kotel9.Òîïêà
Gas compressor (compressor)	kotel9.ÄÑÀ, kotel9.ÄÑÁ, kotel9.ÄÂÀ, kotel9.ÄÂÁ
Heat exchanger (heatExch)	kotel9.ÏÏ, kotel9.ÂÏ1, kotel9.ÂÏ2, kotel9.ÑÏ, kotel9.ÝÊ1, kotel9.ÝÊ2
Valve (klap)	kotel9.3ÂÏ, kotel9.5ÂÏ, kotel9.7ÂÏ, kotel9.5ÃÄ9, kotel9.6ÃÄ9, kotel9.7ÃÄ9, kotel9.8ÃÄ9, kotel9.9ÃÄ9, kotel9.10ÃÄ9, kotel9.3ÃÊ9, kotel9.4ÃÊ9, kotel9.6ÃÊ9, kotel9.5ÃÊ9, kotel9.3ÃÏ9, kotel9.4ÃÏ9, kotel9.5ÃÏ9, kotel9.6ÃÏ9, kotel9.4ÃÏÇ9, kotel9.1Ø9, kotel9.2Ø9, kotel9.11Ø9, kotel9.13Ø9
Network (loading) (net)	kotel9.ParNet, kotel9.Àòìîñô
Pipe 1->2 (pipe1_2)	kotel9.ÓÇ3, kotel9.Óç5, kotel9.Óç6, kotel9.Óç7, kotel9.Óç10
Pipe 2->1 (pipe2_1)	kotel9.ÓÇ1, kotel9.ÓÇ2, kotel9.ÓÇ9, kotel9.Óç12
Pipe 3->1 (pipe3_1)	kotel9.Óç8
Source (pressure) (src_press)	kotel9.SrcÃÄ, kotel9.SrcÃÊ, kotel9.SrcÂîäà, kotel9.SrcÏÃ, kotel9.SrcÂîçäóõ
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 Ê9" (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		Áàðàáàí.Lo
LÑA122, LSA124	The level of water in a clean drum slot, right	%, (0;100), Precision 0	Áàðàáàí.Lo
LSA123	The level of water in a clean drum slot, left	%, (0;100), Precision 0	Áàðàáàí.Lo
LCVG121	3FWL-9 position	%, (0;100), Precision 0	3ÂÏ.l_kl1
LCVG122	3FWR-9 position	%, (0;100), Precision 0	3ÂÏ.l_kl2
G_11SH	11G-9 position		11Ø9.l_kl1
G_12SH	12G-9 position		11Ø9.l_kl2
G_13SH	13G-9 position		13Ø9.l_kl1
G_14SH	14G-9 position		13Ø9.l_kl2
P_5VP	5FW(1) position		5ÂÏ.l_kl1
P_5VP_2	5FW(2) position		5ÂÏ.l_kl2
P_7VP	7FW position		7ÂÏ.l_kl1
P_4GP9	4GN9 position		4ÃÏ9.l_kl1
P_5GP9	5GN9 position		5ÃÏ9.l_kl1
P_7GD	7GBF position		7ÃÄ9.l_kl1
P_8GD	8GBF position		8ÃÄ9.l_kl1
FCVG102	5GN-9 position		5ÃÏ9.l_kl1
FCVG103	7GBF9 position		7ÃÄ9.l_kl1
FCVG104	8GN-9 position		8ÃÄ9.l_kl1
FCVG105	4GC-9 position		4ÃÊ9.l_kl1
TCVG1_1	7FW-9 position		7ÂÏ9.l_kl1
TCVG1_2	5FWL-9 position		5ÂÏ9.l_kl1
PCVG76	SEA productivity	rpm, (0;100), Precision 1	ÄÑÀ.N
PCVG77	SEB productivity	rpm, (0;100), Precision 1	ÄÑÁ.N
FCV106	BFA productivity	rpm, (0;100), Precision 1	ÄÂÀ.N
FCV107	BFB productivity	rpm, (0;100), Precision 1	ÄÂÁ.N
PCA51	Steam pressure after the MSV	at, (0;50), Precision 2	4ÃÏÇ9.Po
PSA52	Steam pressure in the the boiler's drum	at, (0;40), Precision 2	Áàðàáàí.Po1
PCA52	Steam pressure in the boiler's drum	at, (0;50), Precision 2	Áàðàáàí.Po1
PSA52_1	Steam pressure in the boiler's drum	at, (0;40), Precision 2	Áàðàáàí.Po1
PSA53	GN pressure before the regulating valve	at, (0;40), Precision 2	3ÃÏ9.Po
PSA53_1	GN pressure before the diaphragm	at, (0;40), Precision 2	3ÃÏ9.Po
PSA53_2	GN pressure before the diaphragm	at, (0;40), Precision 2	3ÃÏ9.Po
PSA54	GN pressure after the regulating valve	at, (0;1.5), Precision 3	5ÃÏ9.Po
PA55	GN pressure before the left burner	at, (0;40), Precision 2	6ÃÏ9.Po
PA56	GN pressure before the right burner	at, (0;40), Precision 2	6ÃÏ9.Po
PSA57_1, PSA57_2	GBF pressure on the general pipeline.	at, (0;2), Precision 2	ÓÇ3.Pi
PSA59	GBF pressure after valve on the left gas pipeline	at, (1;2), Precision 3	10ÃÄ9.Po
PSA60	GBF pressure after valve on the right gas pipeline	at, (1;2), Precision 3	9ÃÄ9.Po
P61	GBF pressure before the left burner	at, (0;1.6), Precision 2	9ÃÄ9.Po
P62	GBF pressure before the right burner	at, (0;1.6), Precision 2	10ÃÄ9.Po
PSA63_1	GC pressure after 5GC-9	at, (0;2), Precision 2	5ÃÊ9.Po
PSA63_2	GC pressure after 3GC-9	at, (0;2), Precision 2	3ÃÊ9.Po
PSA64	GC pressure after the regulating valve	at, (0;2), Precision 3	4ÃÊ9.Po
P65	GC pressure before the left burner	at, (0;1.6), Precision 2	6ÃÊ9.Po
P66	GC pressure before the right burner	at, (0;1.6), Precision 2	6ÃÊ9.Po
P67	The air pressure before the first stage of A/H to the left.	at, (0;1.2), Precision 2	ÓÇ9.Po
P72	The air pressure in the upper tier of the left burner	at, (0;1.2), Precision 2	ÓÇ2.Po
P68	The air pressure before the first stage of A/H to the right.	at, (0;1.2), Precision 2	ÓÇ9.Po
PSA70	Air pressure after the second stage of air-heater	at, (0;1.2), Precision 2	ÂÏ2.Po2
PSA71	Air pressure after the second stage of air-heater	at, (0;1.2), Precision 2	ÂÏ2.Po2
P73, PSA73	The air pressure in the upper tier of the right burner	at, (0;1.16), Precision 2	ÓÇ2.Po
P74	The air pressure on the lower tier of the left burner	at, (0;1.16), Precision 2	ÓÇ2.Po
P75, PSA75	The air pressure on the lower tier of the right burner	at, (0;1.16), Precision 2	ÓÇ2.Po
PCSA76	The vacuum in the fire chamber on the left	at, (0.9;1), Precision 3	Òîïêà.Po
PCSA77	The vacuum in the fire chamber on the right	at, (0.9;1), Precision 3	Òîïêà.Po
P78	The vacuum in front of "SE-A"	at, (0.9;1), Precision 2	1Ø9.Po
P79	The vacuum in front of "SE-B"	at, (0.9;1), Precision 2	2Ø9.Po
PSA80	FW pressure on the left feeding line	at, (0;60), Precision 2	SrcÂîäà.Po
PSA81	FW pressure on the right feeding line	at, (0;60), Precision 2	SrcÂîäà.Po
PSA85	Air pressure after the air heater	at, (0;2), Precision 3	ÂÏ2.Po2
P103	GBF pressure on the diaphragm on the left	at, (0;2), Precision 2	ÓÇ3.Po2
P104	GBF pressure on the diaphragm on the right	at, (0;2), Precision 2	ÓÇ3.Po1
Src_GP_Pi	The inlet pressure at the source of GN		SrcÏÃ.Pi
P_GP_S	GN pressure after the source		SrcÏÃ.Po
P_GP_4GP	GN pressure after 4GN9		4ÃÏ9.Po
P_3VP_1	3FW9(1) position		3ÂÏ.l_kl1
P_3GP9	3GN9 position		3ÃÏ9.l_kl1
P_6GP9_1	6GN9_1 position		6ÃÏ9.l_kl1
P_6GP9_2	6GN9_2 position		6ÃÏ9.l_kl2
P_5GK	5GC position		5ÃÊ9.l_kl1
Pbar	The pressure in the boiler's drum		Áàðàáàí.Po1
TCA1	Steam temperature after MSV		4ÃÏÇ9.To
F_3VP	Water flow after 3FW		3ÂÏ.Fo
F_5VP	Water flow after 5FW		5ÂÏ.Fo
F_7VP	Water flow after 7FW		7ÂÏ.Fo
Fbar	Water flow into the drum		Áàðàáàí.Fi1
F_UZ8	Water flow after UZ8		Óç8.Fo
FC101	Steam flow from boiler	t/h, (0;100), Precision 2	4ÃÏÇ9.Fo
FC102	Flow of the natural gas after 3GN9		3ÃÏ9.Fo
FC102_0	Natural gas flow after it source		SrcÏÃ.Fo
FC102_1	Natural gas flow after 4GN9		4ÃÏ9.Fo
FC102_2	Natural gas flow after 5GN9		5ÃÏ9.Fo
FC102_3	Natural gas flow after 6GN9		6ÃÏ9.Fo
FC103	GBF flow on the left gas pipeline		5ÃÄ9.Fi
FC104	GBF flow on the right gas pipeline		6ÃÄ9.Fi
FC105	Flow of coke gas after 5GC9		5ÃÊ9.Fo
FC106	Air flow to the left burner	t/h, (0;100), Precision 1	ÓÇ2.Fi1
FC107	Air flow to the right burner	t/h, (0;100), Precision 1	ÓÇ2.Fi2
FA108	The flow of air-superheater on the right feeding line	t/h, (0;200), Precision 2	SrcÂîäà.Fo
F109	Water flow for the thermostat	t/h, (0;200), Precision 2	7ÂÏ.Fo
FA110	The flow of air-superheater on the left feeding line	t/h, (0;200), Precision 2	SrcÂîäà.Fo
QA151	The oxygen content in FG after the superheater	%, (0;20), Precision 2	Òîïêà.O2
QA152	The CO content in FG after the superheater	%, (0;20), Precision 2	Òîïêà.CO
QA153	Oxygen content in the exhaust FG	%, (0;20), Precision 2	Òîïêà.O2
T2	Natural gas temperature	deg.K, (223;323), Precision 2	3ÃÏ9.To
T3	GBF temperature	deg.K, (273;373), Precision 2	5ÃÄ9.Ti
T5	The temperature of the GC before boiler	deg.K, (273;373), Precision 2	4ÃÊ9.To
T7	Air temperature after the second stage of air-heater on the left	deg.K, (273;773), Precision 2	ÂÏ2.To2
T8	Air temperature after the second stage of air-heater on the right	deg.K, (273;773), Precision 2	ÂÏ2.To2
T13	FG temperature before superheater on the left	deg.K, (273;1027), Precision 2	Áàðàáàí.To2
T14	FG temperature before superheater on the right	deg.K, (273;1027), Precision 2	Áàðàáàí.To2
T15	FG temperature before 2 stage of economizer on the left	deg.K, (273;873), Precision 2	ÏÏ.To1
T16	FG temperature before 2 stage of economizer on the right	deg.K, (273;873), Precision 2	ÏÏ.To1
T17	FG temperature after 2 stage of economizer on the left	deg.K, (273;873), Precision 2	ÝÊ2.To1
T18	FG temperature after 2 stage of economizer on the right	deg.K, (273;873), Precision 2	ÝÊ2.To1
T19	FG temperature before the first stage of air-heater on the left	deg.K, (273;873), Precision 2	ÝÊ1.To1
T20	FG temperature before the first stage of air-heater on the right	deg.K, (273;873), Precision 2	ÝÊ1.To1
T21	FG temperature before the second stage of air-heater on the left	deg.K, (273;873), Precision 2	ÝÊ2.To1
T22	FG temperature before the second stage of air-heater on the right	deg.K, (273;873), Precision 2	ÝÊ2.To1
T23	FG temperature before 1 stage of economizer on the left	deg.K, (273;873), Precision 2	ÂÏ2.To1
T24	FG temperature before 1 stage of economizer on the right	deg.K, (273;873), Precision 2	ÂÏ2.To1
TA25	FG temperature before th "SE-A"	deg.K, (273;673), Precision 2	1Ø9.To
TA26	FG temperature before th "SE-B"	deg.K, (273;673), Precision 2	2Ø9.To
T35	The temperature of water on the left feeding line	deg.K, (273;473), Precision 2	3ÂÏ.To
T36	The temperature of water on the right feeding line	deg.K, (273;473), Precision 2	3ÂÏ.To
T37	The water temperature after the economizer on the left	deg.K, (273;673), Precision 2	ÝÊ2.To2
T38	The water temperature after the economizer on the right	deg.K, (273;673), Precision 2	ÝÊ2.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.

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.

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 results was full-featured dynamic model of multi-fuel steam boiler technological process for high pressure and productivity. The model is available at three languages and has been included to OpenSCADA-system distributives for demonstration functions and capabilities.

The model is allow control capability from operator face, include operation:

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

In general, into control scheme, fully work next regulators:

• LC121 — level in the boiler's drum;
• PSA76 — the vacuum in the fire chamber;
• 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 applicable sense the model has been available tests algorithms for control several fuel types flows.

The model's resource intensity is 70% to CPU 800 MHz core, architecture x86.

Links

Referring pages:

HomePageEn/Server
HomePageEn/Using/ModelDMKK9