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Dynamic model-simulator of the steam boiler unit of the metallurgical combine in real time
State:

Founded: January 2007
Version: 2.0 — BlockCalc.{boiler9,boiler9_cntr,CM*0*}, 2.0 — VCA.Boiler
Members: Roman Savochenko
  Maxim Lysenko(2007-2012), Ksenia Yashina(2007-2008)
Description: The project is targeted to create a complete dynamic model-simulator of the steam boiler unit of the Dnepr Metallurgical Combine (DMC).
Address:

  • supplied with Linux distribution packages like to "openscada-model-boiler";
  • directly from the subversion repository and converted to the DB SQLite files in the way:
$ wget http://oscada.org/svn/trunk/OpenSCADA/data/ModelsDB/Boiler/Model.sql
$ sqlite3 -init Model.sql Model.db .exit
Model Boiler so gen.png

The modelling object of this project, for creation the full-scale real time dynamic simulator, is the multi-fuel steam boiler #9 of the Dnepr Metallurgical Combine (DMC). The distinctive feature of the boiler unit is the same multi-fuel nature and, as a consequence — features in optimal control of its load.

1 Purpose

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

Operational purpose of the development is:

  • test of algorithms of the ASC TP control;
  • test of the adequate operating of the SCADA-system;
  • training of technical personnel;
  • "live" demonstration of features and example of a project in the OpenSCADA SCADA-system, as the actual and finite goal, currently.

2 Development

In order to speed up the development, to use the experience of the previous developments, as well as to improve the technology and development tools of the complete dynamic real-time simulators, there was made the decision to build the simulator in the OpenSCADA environment. OpenSCADA has a powerful mechanism of user-side programming, as well as achievements to create a complete real-time dynamic simulators, which allow you to quickly create of large real-time dynamic simulators. For more information, see the concept-library of models of the technological devices.

Conceptually, complex simulators of the technological processes are divided and consist of three distinctly defined structural units, which in practical application are as clearly defined and can be used independently, after joint work, that is (from the bottom to the top):

  • technological process — a real-time mathematical model that describes the work of a technological process in dynamics;
  • Programming Logical Controller (PLC) — in fact, these are algorithms and regulators designed to control the stability of the technological process within the regimes defined by the technological regulations and these are reproduced by the complex simulator;
  • SCADA — Supervisory Control And Data Acquisition system, which is a window to the technological process, receiving data from the PLC and issuing control actions.

2.1 The technological process

Before the creation of the boiler unit simulator the schematic diagram of its technological process was formed, based on the schematic diagram of the real technological process. The scheme is shown in Figure 1.

Fig.1. Technological scheme of the boiler unit #9 of DMK.

2.2 Simulating-modeling

To construct the simulator of the technological process, basing on the available devices models, the original principal diagram and the block calculator (BlockCalc) of OpenSCADA were directly used. The devices models of the technological scheme were appended to the block scheme in accordance with the principal one. Part of the blocks were been added for the auxiliary equipment, as well as for the flow nodes. Numbers of the node blocks on the principal diagram are indicated by numbers near the flow nodes.

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

Table 1. Block-scheme of the simulator

Identifier Name Target Execution period, seconds
boiler9 DMC Boiler9 Contains a simulator of the boiler unit #9 of the Dnepr Metallurgical Combine. 0.005
boiler9_cntr DMC Boiler9 Controller Contains a simulator of the control system of the boiler unit #9 of the Dnepr Metallurgical Combine. 1

Table 2 shows the list of used device models, in accordance with the principle diagram.

Table 2. Models of the used technological devices

Model of the technological device Devices (blocks of the simulator)
The library "Technological devices"
Boiler: barrel (boilerBarrel) boiler9.Drum
Boiler: burner (boilerBurner) boiler9.FireChamber
Gas compressor (compressor) boiler9.SEA, boiler9.SEB, boiler9.BFA, boiler9.BFB
Heat exchanger (heatExch) boiler9.OhS, boiler9.AH1, boiler9.AH2, boiler9.DS, boiler9.EC1, boiler9.EC2
Valve (klap) boiler9.3FW, boiler9.5FW, boiler9.7FW, boiler9.5GBF, boiler9.6GBF, boiler9.7GBF, boiler9.8GBF, boiler9.9GBF, boiler9.10GBF, boiler9.3GC, boiler9.4GC, boiler9.6GC, boiler9.5GC, boiler9.3GN, boiler9.4GN, boiler9.5GN, boiler9.6GN, boiler9.4GN3, boiler9.1G, boiler9.2G, boiler9.11G, boiler9.13G
Network (loading) (net) boiler9.ParNet, boiler9.Atmosph
Pipe 1->2 (pipe1_2) boiler9.Node3, boiler9.Node5, boiler9.Node6, boiler9.Node7, boiler9.Node10
Pipe 2->1 (pipe2_1) boiler9.Node1, boiler9.Node2, boiler9.Node9, boiler9.Node12
Pipe 3->1 (pipe3_1) boiler9.Node8
Source (pressure) (src_press) boiler9.SrcGBF, boiler9.SrcGC, boiler9.SrcWater, boiler9.SrcNG, boiler9.SrcAir
The library "Complex1 functions"
PID regulator (pid) boiler9_cntr.TCA1, boiler9_cntr.F_air_gas, boiler9_cntr.QAC151, boiler9_cntr.LC121, boiler9_cntr.PCA51, boiler9_cntr.FC101, boiler9_cntr.FC102, boiler9_cntr.FC103, boiler9_cntr.FC104, boiler9_cntr.FC105, boiler9_cntr.PSA76
The library "Boiler К9" (JavaLikeCalc.lib_boiler9, with this project)
Divider (Divider) boiler9_cntr.Air_Gas
Total fuel flow in the boiler (Fsum) boiler9_cntr.Fsum
Inversion (Inversion) boiler9_cntr.5FW_inv

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

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

Table 3. Parameters of the technological process

Cipher Description Properties Source
DMC Boiler9 (BlockCalc.boiler9)
LC121 Water level in the boiler drum Drum.Lo
LСA122, LSA124 Level of water in the clean slot of the drum, in the right  %, (0;100), Precision 0 Drum.Lo
LSA123 Level of water in the clean slot of the drum, in the left  %, (0;100), Precision 0 Drum.Lo
LCVG121 3FWL position  %, (0;100), Precision 0 3FW.l_kl1
LCVG122 3FWR position  %, (0;100), Precision 0 3FW.l_kl2
G_11SH 11G position 11G.l_kl1
G_12SH 12G position 11G.l_kl2
G_13SH 13G position 13G.l_kl1
G_14SH 14G position 13G.l_kl2
l_5FW 5FW(1) position 5FW.l_kl1
l_5FW_2 5FW(2) position 5FW.l_kl2
l_7FW 7FW position 7FW.l_kl1
l_4GN 4GN position 4GN.l_kl1
l_5GN 5GN position 5GN.l_kl1
l_7GBF 7GBF position 7GBF.l_kl1
l_8GBF 8GBF position 8GBF.l_kl1
FCVG102 5GN position 5GN.l_kl1
FCVG103 7GBF position 7GBF.l_kl1
FCVG104 8GBF position 8GBF.l_kl1
FCVG105 4GC position 4GC.l_kl1
TCVG1_1 7FW position 7FW.l_kl1
TCVG1_2 5FWL position 5FW.l_kl1
PCVG76 SEA productivity rpm, (0;100), Precision 1 SEA.N
PCVG77 SEB productivity rpm, (0;100), Precision 1 SEB.N
FCV106 BFA productivity rpm, (0;100), Precision 1 BFA.N
FCV107 BFB productivity rpm, (0;100), Precision 1 BFB.N
PCA51 Steam pressure after the MSV at, (0;50), Precision 2 4GN3.Po
PSA52 Steam pressure in the boiler drum at, (0;40), Precision 2 Drum.Po1
PCA52 Steam pressure in the boiler drum at, (0;50), Precision 2 Drum.Po1
PSA52_1 Steam pressure in the boiler drum at, (0;40), Precision 2 Drum.Po1
PSA53 GN pressure before the regulating valve at, (0;40), Precision 2 3GN.Po
PSA53_1 GN pressure before the diaphragm at, (0;40), Precision 2 3GN.Po
PSA53_2 GN pressure before the diaphragm at, (0;40), Precision 2 3GN.Po
PSA54 GN pressure after the regulating valve at, (0;1.5), Precision 3 5GN.Po
PA55 GN pressure before the left burner at, (0;40), Precision 2 6GN.Po
PA56 GN pressure before the right burner at, (0;40), Precision 2 6GN.Po
PSA57_1, PSA57_2 GBF pressure on the general pipeline at, (0;2), Precision 2 Node3.Pi
PSA59 GBF pressure after valve on the left gas pipeline at, (1;2), Precision 3 10GBF.Po
PSA60 GBF pressure after valve on the right gas pipeline at, (1;2), Precision 3 9GBF.Po
P61 GBF pressure before the left burner at, (0;1.6), Precision 2 9GBF.Po
P62 GBF pressure before the right burner at, (0;1.6), Precision 2 10GBF.Po
PSA63_1 GC pressure after 5GC at, (0;2), Precision 2 5GC.Po
PSA63_2 GC pressure after 3GC at, (0;2), Precision 2 3GC.Po
PSA64 GC pressure after the regulating valve at, (0;2), Precision 3 4GC.Po
P65 GC pressure before the left burner at, (0;1.6), Precision 2 6GC.Po
P66 GC pressure before the right burner at, (0;1.6), Precision 2 6GC.Po
P67 Air pressure before the first stage of the A/H to the left at, (0;1.2), Precision 2 Node9.Po
P68 Air pressure before the first stage of the A/H to the right at, (0;1.2), Precision 2 Node9.Po
PSA70 Air pressure after the second stage of the A/H at, (0;1.2), Precision 2 AH2.Po2
PSA71 Air pressure after the second stage of the A/H at, (0;1.2), Precision 2 AH2.Po2
P72 Air pressure in the upper tier of the left burner at, (0;1.2), Precision 2 Node2.Po
P73, PSA73 Air pressure in the upper tier of the right burner at, (0;1.16), Precision 2 Node2.Po
P74 Air pressure on the lower tier of the left burner at, (0;1.16), Precision 2 Node2.Po
P75, PSA75 Air pressure on the lower tier of the right burner at, (0;1.16), Precision 2 Node2.Po
PCSA76 Vacuum in the fire chamber on the left at, (0.9;1), Precision 3 FireChamber.Po
PCSA77 Vacuum in the fire chamber on the right at, (0.9;1), Precision 3 FireChamber.Po
P78 Vacuum in the "SE-A" front at, (0.9;1), Precision 2 1G.Po
P79 Vacuum in the "SE-B" front at, (0.9;1), Precision 2 2G.Po
PSA80 FW pressure on the left feeding line at, (0;60), Precision 2 SrcWater.Po
PSA81 FW pressure on the right feeding line at, (0;60), Precision 2 SrcWater.Po
PSA85 Air pressure after the A/H at, (0;2), Precision 3 AH2.Po2
P103 GBF pressure on the diaphragm on the left at, (0;2), Precision 2 Node3.Po2
P104 GBF pressure on the diaphragm on the right at, (0;2), Precision 2 Node3.Po1
Src_GN_Pi Input pressure at the source of GN SrcNG.Pi
P_GN_S GN pressure after the source SrcNG.Po
P_4GN GN pressure after 4GN 4GN.Po
l_3FW_1 3FW(1) position 3FW.l_kl1
l_3GN 3GN position 3GN.l_kl1
l_6GN_1 6GN_1 position 6GN.l_kl1
l_6GN_2 6GN_2 position 6GN.l_kl2
l_5GC 5GC position 5GC.l_kl1
Pdrum Pressure in the boiler drum Drum.Po1
TCA1 Steam temperature after MSV 4GN3.To
F_3FW Water flow after 3FW 3FW.Fo
F_5FW Water flow after 5FW 5FW.Fo
F_7FW Water flow after 7FW 7FW.Fo
Fdrum Water flow into the drum Drum.Fi1
F_Node8 Water flow after Node8 Node8.Fo
FC101 Steam flow from the boiler t/h, (0;100), Precision 2 4GN3.Fo
FC102 Natural gas flow 3GN.Fo
FC102_0 Natural gas flow after the source SrcNG.Fo
FC102_1 Natural gas flow after 4GN 4GN.Fo
FC102_2 Natural gas flow after 5GN 5GN.Fo
FC102_3 Natural gas flow after 6GN 6GN.Fo
FC103 GBF flow on the gas pipeline left 5GBF.Fi
FC104 GBF flow on the gas pipeline right 6GBF.Fi
FC105 Coke gas flow of after 5GC 5GC.Fo
FC106 Air flow to the left burner t/h, (0;100), Precision 1 Node2.Fi1
FC107 Air flow to the right burner t/h, (0;100), Precision 1 Node2.Fi2
FA108 Air-superheater flow on the right feeding line t/h, (0;200), Precision 2 SrcWater.Fo
F109 Water flow for the thermostat t/h, (0;200), Precision 2 7FW.Fo
FA110 Air-superheater flow on the left feeding line t/h, (0;200), Precision 2 SrcWater.Fo
QA151 Oxygen content in FG after the superheater  %, (0;20), Precision 2 FireChamber.O2
QA152 CO content in FG after the superheater  %, (0;20), Precision 2 FireChamber.CO
QA153 Oxygen content in the exhaust FG  %, (0;20), Precision 2 FireChamber.O2
T2 Natural gas temperature deg.K, (223;323), Precision 2 3GN.To
T3 GBF temperature deg.K, (273;373), Precision 2 5GBF.Ti
T5 GC temperature on the boiler deg.K, (273;373), Precision 2 4GC.To
T7 Air temperature after the second stage of the A/H on the left deg.K, (273;773), Precision 2 AH2.To2
T8 Air temperature after the second stage of the A/H on the right deg.K, (273;773), Precision 2 AH2.To2
T13 FG temperature before the superheater on the left deg.K, (273;1027), Precision 2 Drum.To2
T14 FG temperature before the superheater on the right deg.K, (273;1027), Precision 2 Drum.To2
T15 FG temperature before the second stage of the economizer on the left deg.K, (273;873), Precision 2 OhS.To1
T16 FG temperature before the second stage of the economizer on the right deg.K, (273;873), Precision 2 OhS.To1
T17 FG temperature after the second stage of the economizer on the left deg.K, (273;873), Precision 2 EC2.To1
T18 FG temperature after the secind stage of the economizer on the right deg.K, (273;873), Precision 2 EC2.To1
T19 FG temperature before the first stage of the A/H on the left deg.K, (273;873), Precision 2 EC1.To1
T20 FG temperature before the first stage of the A/H on the right deg.K, (273;873), Precision 2 EC1.To1
T21 FG temperature before the second stage of the A/H on the left deg.K, (273;873), Precision 2 EC2.To1
T22 FG temperature before the second stage of the A/H on the right deg.K, (273;873), Precision 2 EC2.To1
T23 FG temperature before the first stage of the economizer on the left deg.K, (273;873), Precision 2 AH2.To1
T24 FG temperature before the first stage of the economizer on the right deg.K, (273;873), Precision 2 AH2.To1
TA25 FG temperature before the "SE-A" deg.K, (273;673), Precision 2 1G.To
TA26 FG temperature before the "SE-B" deg.K, (273;673), Precision 2 2G.To
T35 Temperature of the A/H on the left feeding line deg.K, (273;473), Precision 2 3FW.To
T36 Temperature of the A/H on the right feeding line deg.K, (273;473), Precision 2 3FW.To
T37 Water temperature after the economizer on the left deg.K, (273;673), Precision 2 EC2.To2
T38 Water temperature after the economizer on the right deg.K, (273;673), Precision 2 EC2.To2
DMC Boiler9 Controller (BlockCalc.boiler9_cntr)
TCA1 Steam temperature at the output K, (273;800), Precision 0 TCA1.*
QAC151 Percentage of oxygen in the flue gases  %, (0;15), Precision 1 QAC151.*
LC121 Level in the boiler drum  %, (0;100), Precision 1 LC121.*
5FW  %, (0;100), Precision 1 5FW_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 Blast furnace gas flow on the left gas pipeline t/h, (0;70), Precision 1 FC103.*
FC104 Blast furnace gas flow on the right gas pipeline t/h, (0;70), Precision 1 FC104.*
FC105 Coke oven gas flow t/h, (0;10), Precision 1 FC105.*
PSA76 Vacuum in the fire chamber at, (0.9;1), Precision 3 PSA76.*

2.3 Regulation

The dynamic model-simulator itself may be unstable without control. For example, the parameter of the drum level does not have the self-regulation and goes to extremes in the case of the balance absence in the control parameters, which is typical of a pure integral. For this reason, as well as to create a self-sufficient simulator capable of operating autonomously and without the PLC as a regulator, an object was created for the regulators controller for the boiler simulator in accordance with the regulation schemes in Figure 2-4.

Fig.2. Regulation of the drum level and steam temperature.
Fig.3. Regulation of the fire chamber rarefaction.
Fig.4. Regulation of steam and gases flows.

3 User interface

User interface of the simulator contains eleven signal objects (Fig.5). Each object contains several mnemonic cadres, graphic groups, contour groups and overview groups.

Fig.5. General view of window of the user interface.

3.1 Signal object "Start"

Fig.6. Mnemonic scheme of the signal object "Start".
Fig.7. Graphics group of the signal object "Start".
Fig.8. Contours group of the signal object "Start".
Fig.9. Overview group of the signal object "Start".

3.2 Signal object "Firing"

Fig.10. Mnemonic scheme of the signal object "Firing".
Fig.11. Graphics group of the signal object "Firing".
Fig.12. Contours group of the signal object "Firing".
Fig.13. Overview group of the signal object "Firing".

3.3 Signal object "Flue Gases"

Fig.14. Mnemonic scheme of the signal object "Flue Gases".
Fig.15. Mnemonic scheme 2 of the signal object "Flue Gases".
Fig.16. Graphics group of the signal object "Flue Gases".
Fig.17. Contours group of the signal object "Flue Gases".
Fig.18. Overview group of the signal object "Flue Gases".

3.4 Signal object "Drainages"

Fig.19. Mnemonic scheme of the signal object "Drainages".
Fig.20. Graphics group of the signal object "Drainages".
Fig.21. Contours group of the signal object "Drainages".
Fig.22. Overview group of the signal object "Drainages".

3.5 Signal object "GBF"

Fig.23. Mnemonic scheme of the signal object "GBF".
Fig.24. Graphics group of the signal object "GBF".
Fig.25. Contours group of the signal object "GBF".
Fig.26. Overview group of the signal object "GBF".

3.6 Signal object "GN"

Fig.27. Mnemonic scheme of the signal object "GN".
Fig.28. Graphics group of the signal object "GN".
Fig.29. Contours group of the signal object "GN".
Fig.30. Overview group of the signal object "GN".

3.7 Signal object "GC"

Fig.31. Mnemonic scheme of the signal object "GC".
Fig.32. Graphics group of the signal object "GC".
Fig.33. Contours group of the signal object "GC".
Fig.34. Overview group of the signal object "GC".

3.8 Signal object "STEAM"

Fig.35. Mnemonic scheme of the signal object "STEAM".
Fig.36. Graphics group of the signal object "STEAM".
Fig.37. Contours group of the signal object "STEAM".
Fig.38. Overview group of the signal object "STEAM".

3.9 Signal object "FW"

Fig.39. Mnemonic scheme of the signal object "FW".
Fig.40. Graphics group of the signal object "FW".
Fig.41. Contours group of the signal object "FW".
Fig.42. Overview group of the signal object "FW".

3.10 Signal object "Economizer"

Fig.43. Mnemonic scheme of the signal object "Economizer".
Fig.44. Graphics group of the signal object "Economizer".
Fig.45. Contours group of the signal object "Economizer".
Fig.46. Overview group of the signal object "Economizer".

3.11 Signal object "AirSup"

Fig.47. The mnemonic scheme "Air Supply" of the signal object "AirSup".
Fig.48. The mnemonic scheme "Air Supply control" of the signal object "AirSup".
Fig.49. Graphics group of the signal object "AirSup".
Fig.50. Contours group of the signal object "AirSup".
Fig.51. Overview group of the signal object "AirSup".

4 Results

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

The model envisages the ability to control the TP on behalf of the operator, including operations:

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

In general, in the control scheme, the following regulators are fully involved:

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

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

Resource intensity of the simulator in whole, to the CPU Athlon 64 3000+ (2000MHz) is 22%, to the CPU 800 MHz is 70%.

5 Links