Strojniski vestnik - Journal of Mechanical Engineering 56(2010)9, 565-574 UDC 621.182 Paper received: 29.01.2008 Paper accepted: 31.08.2010 Robust IMC Controllers with Optimal Setpoints Tracking and Disturbance Rejection for Industrial Boiler Dejan D. Ivezic1, Trajko B. Petrovic2 1 University of Belgrade, Faculty of Mining and Geology Engineering, Department for Mechanical Engineering 2 University of Belgrade, Faculty of Electrical Engineering, Department for Control Engineering Robust controllers based on Internal Model Control (IMC) theory are developed in this paper to improve the robust performance of industrial boiler system against uncertainties and disturbances. A simplified model of a boiler's drum unit is developed and transfer matrix realization of its dynamics is obtained for a nominal operational condition. Controllers parameters are selected in accordance with the frequency domain optimization method based on ¿u-optimality frameworks. The proposed controllers are robust for reference signals and/or for disturbances. Finally, a comparison between the performances of the closed-loop system with designed IMC controllers is obtained. ©2010 Journal of Mechanical Engineering. All rights reserved. Keywords: industrial boiler, robust control, internal model control 0 INTRODUCTION The main aim of this work is to present the problem and to devise a method for designing robust IMC controllers of industrial boiler subsystem using the frequency domain optimization method based on ¿ -optimality framework. Various control techniques have been applied to boiler or boiler-turbine controller design, e.g., inverse Nyquist array [1], linear quadratic Gaussian (LQG) [2], LQG/loop transfer recovery (LTR) [3], mixed-sensitivity approach [4], loop-shaping approach [5], and predicative control [6]. The ¿ -optimality framework takes into account the system's nominal plant model, incorporating real and complex uncertainties, which describe interested parameter variation range to ensure that the closed-loop with the controller is stable with a certain degree of performance over all possible plants. A brief introduction to the robust control theory and its application on the distillation column, dc/dc converters and solid-fuel boiler are given in [7] to [15]. The boiler studied is an industrial boiler system with a normal steam production of 8.7 kg/s and with an outlet steam pressure and a steam temperature of 18.105 Pa and 400°C. Set of nonlinear equations for describing the boiler's subsystem (steam-water part) dynamics is presented. The Boiler model, in the form of transfer functions matrixes is developed by linearization around the operating point. For this multivariable model, IMC controllers (IMCr,0, IMC0,d, IMCr,d) are designed. The controllers are proposed for three opposite goals. The first controller (IMCr,0) is designed for optimal setpoint tracking, the second (IMC0,d) for optimal disturbance rejection and the third (IMCr,d) for optimal overcome of the trade-off between these opposite demands. The final goal is to compare the robustness of closed-loop systems with IMCr,0, IMC0,d, IMCr,d controllers using frequency analysis and to verify the results using transient analysis. 1 THE PROCESS AND ITS MODEL In the literature, modeling of boilers has been treated in many different ways, [16] to [20]. The boiler process consists of water heater, steam drum, downcomers tubes, mud drum, riser tubes, and superheater (Fig. 1). However, in this paper only the steam-water part (i.e. steam drum, downcomers and risers) is taken into account (Fig. 2), because the water heater and the super heater system are weakly coupled to the steam-water system and it is natural to treat the three systems separately. The input variables are the powder coal flow rate, the feedwater flow rate and the steam flow rate. The output variables are the drum level and the drum pressure. *Corr. Author's Address: University of Belgrade, Faculty of Mining and Geology, Djusina 7, Belgrade 11000, 565 Serbia, ivezic@rgf.bg.ac.rs Fig. 1. Industrial boiler system Mw 1 Ms Mdow, Hdow V ' 0 Mcoal, Qrw Fig. 2. A simplified description of the steam-water part of the boiler system The mass balance of the water in the drum determines the dynamics of the water mass: d_ dt Vdw =- J_ pdw ((1 -Xo)Mo + Mw -MdoW) The drum water level is given by: Vd - Vdw = Adhd. (1) (2) where Vd is the reference volume of water in the drum at nominal point. The mass flow rate of steam condensing in the drum is neglected, that is: ""7~(Vdwpdw) ~ pdw ~T Vdw . dt dt (3) The dynamics of the steam density is taken from the mass balance in the drum: d (Vdspds ) « X0M0 -Ms . dt As the volume of the drum is constant, an increase of steam volume results in a decrease of water volume and vice versa: d d —Vds +—Vdw = o. dt dt (5) A combination of Eqs. (1) and (4) gives: d Pds = [(Mo + Mw - Mow - Ms) + dt Vr„ - V, dt dw (Pds - P dw ) d (6) Vw Pdw dt From the steam table, for known pds, it is possible to find a corresponding drum pressure. The water in the drum is not in the saturation state, and the energy balance is: d(PdwVdwHdw) = Mo(1 -Xo)Hw -dt -MdowHdow + MwHewo . (7) It is presumed that the feedwater temperature is constant, i.e. Hevo = const. This is a rational proposition as the water heater has its own control system. The combination with Eq. (1) gives the dynamics of the drum water enthalpy: PdwVdw^Hdw = M o(1 - X o)(H rw - Hdw ) + dt (8) +Mw (H„o - Hd„ ). Water density, pdw is determined with an assumption of a saturation condition and pdw is then the function of drum pressure. The energy balance of the steam-water mixture in the raisers is: d(p H )V = M, H, + i, rm rm' r dow dow srw dt (9) +Qw - M o( H^ + X or). Hrw and r (evaporation heat) are functions of drum pressure. Heat flow to the risers is assumed to be a function of the powder coal flow rate: Qrw = krwMcoal . The enthalpy of steam-water mixture is a function of the steam quality: H = Hrw + (Hrs - Hrw )X . (11) H Hrs is a function of the drum pressure and if steam quality is considered as linearly distributed along the raisers, the average enthalpy in raisers is: H = H +rX o vvn ' 2 -H dt rm Vr- Eq. (9) can now be written as: 1 [Qw - Mow (Hrm - How ) " -M orj^] (12) (13) The density of the steam-water mixture is given by: +x ( -L —L) P rm — rw — rs — rw (14) Mass flow rate in downcomers is shown by the Bernouli's equation: mdow - Kj^w —r (15) where kc represents the inverse of the circulation losses. Steam-water flow at the top of the risers (M0) can be obtained from mass and energy balance of the risers. To simplify, it is assumed that it can be approximated by the empiric expression: M o - Mdow - AM o + kMou + k3 Ms (16) where AM0 is transient contribution to M0: d ,,AMo - T \k\Moil + k2Ms - AM, dt T o J 3 where time (T) and gain (kj, k2) factors are load dependent, and can be estimated from plant recordings. The set of nonlinear Eqs. (1), (6), (8), (13) and (17) the present state space description of the industrial boiler subsystem. The state vector's elements are: hd - drum water level; Hw - drum water enthalpy; pds - drum steam density; Hrm -average enthalpy of steam-water mixture in risers; aM0 - transient contribution to the steam-water flow rate in risers. Transfer matrix, as a description of boiler subsystem dynamics is obtained by linearization for nominal working conditions, given in Table 1. y - P(s)u + Pdd, P(s): o.o48s A(s) - o.386s 1.119s2 -o.8247s 1ooo • A(s) 1.92s 2-1.71s + o.2oo7 A(s) 1ooo • A(s) A(s) - 1oos3 + 1o.8s2 + o.o8s (18a) (18b) (18c) Table 1. Boiler's working conditions Steam drum Downcomers Input water flow rate Mw [kg/s] 8,7 Water enthalpy Hdow [kJ/kg] 21oo Input water enthalpy Hewo [kJ/kg] 463 Water flow rate Mdow [kg/s] o,18 Water level hd [m] o,75 Volume ^d [m3] 9,54 Risers Water surface size Ad [m2] 8,1o Water enthalpy Hrw [kJ/kg] 21oo Water volume V-w [m3] 4,76 Steam quality Xo [kg/kg] o,75 Pressure Pd [Pa] 2o^1o5 Volume Vr [m3] o,o3x3oo Water density —dw [kg/m3] 849,9o Mixture enthalpy Hrm [kJ/kg] 3125,oo Water temperature T-w [°C] 212,37 Mixture flow rate Mo [kg/s] o,18 Water enthalpy H-w [kJ/kg] 9o8,5 Transient contribution AMo [kg/s] o,11 Steam density —ds [kg/m3] 1,oo Heat flow Qw [kW] 16.447,35 Steam flow rate Ms [kg/s] 8,7o Coal flow rate Mcoal [kg/s] 1,866 Pd (s) = - 0.0002437 s + 0.008 0.0409(s - 0.006) s(s + 0.1) (18d) The following notations are used: Output vector y = [y y2]T y1 -pd, drum pressure; y2 - hd, drum-water level Input vector u = [u u2]T u1 - Mcoah fuel flow rate; u2 - Mw, water flow rate Distrubance d - Ms, steam flow rate The goal of the control law is to generate u1 and u2 so that it maintains y1 and y2 close to setpoint r = [y1ref y2re] and insensitive to disturbance d. 2 THE MODEL UNCERTAINTY The description of the model uncertainty arises from the fact that process plant operates with certain flow rates (coal and water) on its inputs. Changes on inputs are effected by servo-controlled valves, which rely on the measurement of the flow. Existing of 1% error in flow measure produces 10% error in required variation [8]. Thus, our plant model, which describes changes about some operating point is subject to errors of up to 10% on each input channel. Since the error on each input channel is independent of the others, the suitable representation of the disagreement between the real plant P and model P is described by a multiplicative input perturbation L and structured model uncertainty description of multivariable model P . P = P ( I + L) = P(I + /A ), ) < 1. (19) /u = diag(/,/), / = 0.1, represents the uncertainty weighted operator (the frequency dependent magnitude bound of Au) and Au = diag (Aj, A2) is unknown unity norm bounded block diagonal perturbation matrix that reflects the structure of the uncertainty. Also, such description of uncertainty covers the neglected heat capacity of the riser metal, i.e. it was included in the uncertainty of fuel flow. 3 THE PERFORMANCE OBJECTIVE The sensitivity weighting operator Wp is selected by a designer to give a preferred shape to the sensitivity operator E. The feedback system satisfies robust performance if the ro-norm of the weighted sensitivity operator is unity bounded for any perturbation Au of the plant: WPE = sup o(WvE) < 1, for any Au (20) The required limiting values of the closed-loop time constant of the closed-loop system give the following term of weighted sensitivity operator: Wp = 0.2550S+11 p 50s (21) The weight (21) implies that we require an integral action (Wp(0) = ro) and allow an amplification of disturbances at high frequencies by a factor four at most (Wp(ro) = 0.25). A particular sensitivity function, which matches the performance bound (21) exactly for low frequencies, is E = . (22) 200s +1 This corresponds to a first order response with time constant 200 s. 4 IMC IN THE /¿-OPTIMALITY FRAMEWORK The IMC structure was developed in [7] as an alternative to the classic feedback structure. Its main advantage is that closed-loop stability is guaranteed simply by choosing a stable IMC controller. This concept is based on an equivalent transformation of the standard feedback structure into IMC structure shown in Fig. 3 a. The synthesis and analysis of robust IMC controllers, based on the structured singular value approach, impose a forming interconnection matrix by rearrangement of the block diagram of the IMC control structure shown in Fig. 3a in general G-A form (Fig. 3b) necessary for /-analysis. The interconnection matrix G in Fig. 3b is partitioned into four blocks consistent with the dimensions of the two input and the two output vectors: ÙÛ Controller C •0.-H Q S Ap W Au A G (b) Fig. 3. The block diagram of IMC control structure a) and G-A form; b) in accordance with ¿u-optimality framework G = G11 G12 ,G21 G22 (23) The input vector of G consists of the outputs from the uncertainty block Au and the desired external input v (setpoints, disturbance or both). The output vector of G is formed by the inputs to the uncertainty weighted error e'. Form of matrix A is: A = A u 0 A 0 block Au and the (24) where Ap is a full unity norm bounded matrix ä(A ) < 1. The ^-optimality framework adopts measures of robust stability (RS) and robust performance (RP) as suitable objectives [7] and [10], which define the performance of the multivariable feedback system in the presence of structured uncertainty: RS = ||r5(®)|[= \\Gu\\m = sup^(Gn) <1, (25) & RP = |\rp(a,)\\b = ||G|L = sup ^ (G) < 1- (26) & The operator /uA is a structured singular value (L-norm) computed according to the blockdiagonal structure of A [7], [8] and [10] ^-norm is the natural extension of ro-norm when both the bound and the structure of model uncertainty are known. The upper bound of j-iA(G) is defined as jua(G)