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District heating
3
1 2
5
6
4
Heat value G
correction 6
- Brown coal
- Refuse
Calculation-guided Closed-loop Control Systems furnace operation setpoint control. Model errors are corrected by
the secondary setpoint controllers of all major process areas, such
Fields of application and characteristics as FD floating pressure, turbine extraction pressure, heating
condenser pressure.
• Condensate stop control
• District heating supply from cogeneration Observer-based State Control
Calculation-guided closed-loop controls are primarily used in Field of application and characteristics
complex power station heat circuits where often contrasting task
definitions have to be taken into account: • Live steam temperature control
• Fast and opposite load variations at the consumer end, • Intermediate superheater temperature control
e.g., turbines / generator and district heating system
• Control loops with highly load-dependent time constants and of
• Slow increase of the steam generator output higher system order
Using conventional closed-loop control circuits responding to The state controller with observer is used for higher-level processes
system deviations, these tasks can only be solved with a maximum with self-regulation, but can also be used for processes with dead
effort in the planning and commissioning phases. They also hinder time. The process/plant-specific disturbance analysis is carried out
a dynamic operation of the plant. by an internal state observer and the analysis result is taken into
The block model assigns parameters on the basis of the account when the manipulated variable is generated. Actuator
technological design specifications, supplies reference input non-linearity, system dead time, etc. are taken into account by
variables for all control loops of the meshed system - right up to the internal compensation circuits so that a persisting system deviation
is avoided. An online parameter adaptation derives the optimal
PID Controller versus State Controller with Observer • User-friendly and objective parameter setting and optimization
concept
Analog, standard algorithm PID control on a pneumatic, hydraulic
or electronic basis has proved its worth over many years, and is still Performance Comparison using an Application Example
first choice in daily control circuit design even in the days of digital
process control systems. Despite the fact that the PID controller In this section we compare the performance of a Mauell state
structure is not adapted to the controlled process and its setting controller with that of a PID controller. In our example the
parameters do not allow to draw direct conclusions on the control controllers are used for the live steam temperature control of a
quality, points in favour of its use are the detailed knowledge on steam generator, which is characterized by large and highly load-
how the PID controller works, and the many years of experience dependent time constants, a higher system order (n = 3....5 typ.),
that provide plant engineers with the intuitive feel for tuning. external disturbances due to fluctuations in the heating of the
superheater, and high demands on the control quality.
In this report, we confront the well-established technique (PID
control) with the new technique (observer-based state control) and The application example will also demonstrate the versatility of the
show that an alternative exists for the PID controller that is equally Mauell state controller with respect to the fields of application and
practical but more robust to unpredictable changes in the behaviour its suitability for all aperiodic systems with compensation or dead
of the controlled system (e.g., superheater processes). times. It will show that the state controller offers clear advantages
when used in higher-order systems and control loops with long
Based on the state controller described in technical literature and dead times and actuator-dependent non-linearities.
many application reports, Mauell extended the observer concept of
the state controller by implementing essential features that have not The effect of the two alternative control concepts is illustrated for a
been fully documented in the past. steam generator with a two-line superheater (see figure below).
• State observer
• Disturbance observer
• Actuator observer
Example of a steam generator with a two-line superheater, displayed on the ME-VIEW operator control and monitoring system. Line 1 is
equipped with a PID controller, line 2 with state controller.
Te Ta
- Ta soll
State observer DTa
+
-
h1 x h2 x h3
x
+ + +
T1 T2 T3
k1 k2 k3
x x x
Te, soll + +
PI -
State controller
Mauell State Controller with Observer (MZR) The additive connection of the state observer’s integrator output for
the elimination of the steady-state deviation is expressed by the
The Mauell state controller has inherited the basic structure of the factor k0. As the calculation of the factor k0 takes the transfer
conventional state controller which has been extended by function of the controlled system into account, inaccuracies in the
additional structural features. These new features are described in elimination of the system deviation must be expected.
the following.
Due to the fact that deviations in the steady state between the
Elimination of the Steady-state Observer Error controlled system and the model in the state observer are taken
into account by the disturbance observer, model errors, especially
In order to eliminate the steady-state observer error (∆Ta - T3), the gain factor deviations, have no influence on the control precision of
basic structure of the observer concept is extended by a the steady-state controlled system.
disturbance observer so that the observer error ∆Ta - T3 converges
towards zero. Compensation of the Non-linearities of Secondary Follower
Controllers and Actuators
Elimination of the Steady-state System Deviation
To make the state controller robust to non-linear variations of the
For known disturbances on the controlled system, the steady-state follower controller and actuator, a so-called actuator observer has
deviation of a state controller can be determined from the transfer been implemented.
function of the controlled system and the parameters of the state
controller. The actuator observer has the task of varying the state variables
T1 to T3 so that they can be used for the determination of the state
As the disturbances are statically mapped by the state observer, it controller’s manipulated variable without showing any signs of the
is possible to evaluate the contents of the integrator and as a result secondary control loop’s dynamic behavior.
compute the ‘± change’ of the state controller’s state variable in
order to eliminate the steady-state system deviation. Therefore, within the framework of the overall cascade, the
secondary control loop has only a delaying effect. It does not affect
In this context, the reference input variable can also be considered the stability of the state controller.
as a disturbance in the sense of a shift of the neutral position.
These observations formed the basis for the development of the
Mauell state controller.
Te Ta
Ta,soll
Load balancing
n Order
h0 h1 h2 h3
X X X X ks Gain
T Denominator
time constant
T1 T2 T3 Tt Dead time
State controller Tz Numerator
k0 k1 k2 k3
time constant
X X X X
from the system
PI identification
model
l1 l2 l3
X X X v
-
Mauell state controller (implemented in a 3rd order controlled system) with its internal structure adapted to the order of the controlled
system
Controlled system
Controlled system model
Step change
inquiry System parameters:
M - System order n
MU
- Gain factor k s
- Denominator time constant Tn
- Numerator time constant Tz
- Dead time Tt
analog
X D
A Y A
Controller model
D W
Setpoint
Controller in PLS Kp tn tv generator
Structure of the controlled system and controller model generation for the optimization of the setting parameters
Via menu the stored measuring values are loaded for the
identification of the controlled
system together with their time
specification and recording
information. The actual
identification starts with the
marking of the point of time
when the step change was
applied (change of the
manipulated variable).
The automatic determination of
the model parameters is
completed as soon as the optimal
model quality is reached, i.e., if
the error area between the
simulated behavior of the
controlled system on the basis of
the mathematical model and the
measuring data set of the step
response is at a minimum.
The parameters of the controlled
system are also displayed.
Graphical configuration interface with online process data for entering the controlled system parameters as well as the speed factor V.
PID Controller
The alternative control loop with PID controller has also been The optimization procedure starts with the simulation of the closed
optimized on the basis of the data of the controlled system control loop as a response to a step change of the reference
identification. Supplementary to the procedure for the state variable. The program provides you with a continuous graphical
controller, the program module Controller Design has been representation of the optimization sequence.
employed.
The optimization procedure is completed as soon as the specified
The program module Controller Design allows you determine quality criteria are reached, supplying the optimal controller setting
optimal parameters for P, I, PI, PD and PID controllers on the basis parameters (see diagram below):
of the system model from the controlled system identification.
P component Proportion. coefficient kP
The first step is to select the system model of the ‘Controlled I component Reset time Tn [s]
system identification’ process. The program loads a graphical D component Setup time TV [s]
representation of the system model.
Deriving the optimal setting parameters kp, Tn, Tv for a PID controller with the help of the Controller Setup Tool
Detail diagram of the PID controller in the ME-VIEW operator control and monitoring system (line 1 of the superheater)
Mauell State Controller (MZR) It was not necessary to implement feed forward control.
The analysis of the model parameters n and k and the load- Assessment of the Mauell State Controller
dependent parameter T specified for the state controller revealed a
very good model adaptation. The controller results can be characterized as follows:
The advantages of the actuator observer have been proved true as • Rise time Shorter than for the PID
only the superheater behavior from the superheater inlet • Setting time Much shorter than for the PID
temperature to the superheater outlet temperature had to be taken
into account for the parameter assignment of the state controller. • Overshoot 0%, always with asymptotic
damping and thus a good
condition for a smooth process
Possible variations from the secondary injection control, the
injection cooler and the actuator, are not taken into account in this • Error area Much smaller than for the PID
model. This increases the model quality considerably as difficult to • Actuator movements Accurate, even, allowing
model nonlinearities can be neglected. temperature adjustment with
minimum feed water quantity.
The initially selected presetting for the speed factor V (initial value • Commissioning Similar to the PID
1.5), that corresponds to the maximum value of the concurrent PID
• Operating point independence Can be compensated for by
controller, could be increased to the speed factor V = 3.5.
adjusting the load-dependent
system time constant T.
Optimization complexity
The speed factor V is the only setting parameter that affects the
dynamic behavior of the control loop. The adaptation of this
parameter does not require any specific knowledge.
Detail diagram of the MZR controller in the ME-VIEW operator control and monitoring system (line 2 of the superheater)
TSetpoint
[t/h] Time
Time
Qualitative comparison of the controller results TA - Tr / ZR (state controller) and TA - Tr PID (PID controller)
The state controller with observer can be retrofitted to boilers with The above comparison between a PID controller and a Mauell
conventional process control system (hard-wired control and state controller showed that the Mauell state controller with
analog feedback system with control console operating elements) observer has clear advantages when used in complex systems that
as well as to newer plants with digital process control system and would be difficult to control using standard algorithms.
video terminals, simply by integrating a module of the ME 4012
digital process control system in the existing control systems. The The control behavior illustrated in the example has been verified by
existing connections between the control room, controller modules concrete industrial applications and proven its worth. Mauell
and servo drives remain unchanged. The integration can be observer-based control is for example implemented since October
carried out while the system is operating provided the necessary 1996 in block 5 (coal-/oil-fueled, 420t/h steam capacity) of the
preparations have been made. Hafen power plant, Stadtwerke Bremen AG.
It is also possible to integrate the Mauell state controller on the Other applications, like for example the four boilers and the 1000t/h
basis of a Mauell hardware platform so that the plant operator is steam generator of the waste-fueled power station of AWG
provided with the familiar operator control and signalizing concept. Wuppertal, confirm the successful employment of the Mauell state
The communication with the third-party system is established over controller with observer.
a serial or parallel-wire connection. The parameters can be
assigned online.
Mauell AG
Furtbachstraße 17 Mauell Ltd.
CH-8107 Buchs P.O. Box No. 183
Switzerland GB-Calne, SN11 9BZ
Tel. +41 (0)1 847 42 42 Wiltshire/Great Britain
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Mauell Corporation
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Dillsburg PA 17019
USA
Tel. +1717 4 32 86 86
Fax +1717 4 32 86 88
E-Mail gms@mauell-us.com To obtain our latest list of branch offices and
sales representatives in both Germany and abroad:
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Estr. Est. Salvador de Leone, 2998 email us at: info@mauell.com
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Tel. +55 (0)11 79 47-17 77
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