PID Controllers, 2nd Edition

Chapter 7.3.2 - Control Paradigms: Applications

Applications

In many process control applications there are several processes in series. In such cases it is often easy to measure disturbances and use feedforward. Typical applications of feedforward control are: drum-level control in steam boilers, control of distillation columns and rolling mills. An application of combined feedback and feedforward control follows.

EXAMPLE 7.5 Drum level control

A simplified diagram of a steam boiler is shown in Figure 7.7. The water in the raiser is heated by the burners. The steam generated in the raiser, which is lighter than the water, rises toward the drum.

07_3-7.jpg

Figure 7.7 Schematic diagram of a drum boiler with level control.

This causes a circulation around the loop consisting of the raisers, the drum, and the down comers. The steam is separated from the water in the drum. The steam flow to the turbine is controlled by the steam valve.

It is important to keep the water level in the drum constant. Too low a water level gives insufficient cooling of the raisers, and there is a risk of burning. With too high a water level, water may move into the turbines, which may cause damage. There is a control system for keeping the level constant. The control problem is difficult because of the so-called shrink and swell effect. It can be explained as follows: Assume that the system is in equilibrium with a constant drum level. If the steam flow is increased by opening the turbine valve, the pressure in the drum will drop. The decreased pressure causes generation of extra bubbles in the drum and in the raisers. As a result the drum level will initially increase. Since more steam is taken out of the drum, the drum level will of course finally decrease. This phenomena, which is called the shrink and swell effect, causes severe difficulties in the control of the drum level. Mathematically it also gives rise to right half plane zero in the transfer function.

The problem can be solved by introducing the control strategy shown in Figure 7.7. It consists of a combination of feedback and feedforward. There is a feedback from the drum level to the controller, but there is also a feedforward from the difference between steam flow and feed-water flow so that the feedwater flow is quickly matched to the steam flow.

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