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Research Papers: Co-generation/Systems

Boilers Optimal Control for Maximum Load Change Rate

[+] Author and Article Information
Moustafa Elshafei, Iyad Al-Zaharnah, Medhat A. Nemitallah

King Fahd University of Petroleum & Minerals,
Dhahran 31261, Saudi Arabia

Mohamed A. Habib

King Fahd University of Petroleum & Minerals,
Dhahran 31261, Saudi Arabia
e-mail: mahabib@kfupm.edu.sa

1Corresponding author.

Contributed by the Advanced Energy Systems Division of ASME for publication in the JOURNAL OF ENERGY RESOURCES TECHNOLOGY. Manuscript received September 25, 2012; final manuscript received April 19, 2014; published online May 13, 2014. Assoc. Editor: Mansour Zenouzi.

J. Energy Resour. Technol 136(3), 031301 (May 13, 2014) (9 pages) Paper No: JERT-12-1216; doi: 10.1115/1.4027563 History: Received September 25, 2012; Revised April 19, 2014

In many cogeneration systems, one or more boilers are used in hot standby to meet the plant demand of steam in case of failure or upset in the cogeneration unit. Such boilers need to quickly respond to sudden and large steam load changes. However, fast changes in the firing rate cause transient changes in both the drum-boiler steam pressure and drum level, in addition to the potential of developing of thermal stresses in the walls of steam risers. A genetic algorithm (GA) based optimization scheme is proposed for tuning the conventional boiler control loops to maximize the ability of the boiler to respond to large steam demand while keeping the fluctuations in pressure, drum level, and feed rate within acceptable operation limits. A nonlinear model for an actual boiler is first built, validated, and then, it is used to demonstrate the performance of the boiler with the proposed control loop optimization.

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Figures

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Fig. 1

A cogeneration unit using gas turbine

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Fig. 2

Schematic diagram of a drum boiler

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Fig. 3

Three elements boiler water level control

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Fig. 4

Boiler control loops; (a) drum pressure control and (b) water level control

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Fig. 5

Simulated model results versus actual responses of the boiler for different operating parameters

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Fig. 6

Performance of the boiler before and after optimization of the control system

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Fig. 7

Comparison between the actual and simulated results for both the drum level (left), and the feed water flow rate (right)

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