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WI
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F E A T U R E
lectricity generation from solar energy is currently one of the main research areas in the field
of renewable energy. Such systems require reliable control systems to maintain desired operating conditions in the face of changes in solar
radiation. Parabolic trough collectors, which are
the most developed line-focus concentrating solar collectors, are used to feed industrial heat processes thermally.
At present, parabolic reflectors can operate at temperatures up to around 400 C by concentrating the direct
solar radiation onto a tube through which a fluid is
pumped and heated (see Figure 1). Optical concentration
reduces the absorber surface area relative to the collector
aperture area and thus significantly reduces thermal losses. This optical concentration requires the collector to
rotate about a tracking axis, following the daily movement
of the sun. Since only direct solar radiation is optically
April 2004
Parabolic Troughs
0272-1708/04/$20.002004IEEE
IEEE Control Systems Magazine
15
Acronyms
DISS
DSG
FFFV
FFIV
MISO
PI
PID
PSA
SEGS
SISO
Steel Structure
Parabolic Trough
Absorber
16
April 2004
Nomenclature
April 2004
Acol
E
K
Lcol
Lloop
P
T
Tamb
Tav
Ti
Tin
Tin c
Tinj
Tout
Tref
Sabs
afv
aiv
apv
em in
eT
hin
hin
hinj
hout
href
min
min c
minj dem
minj
set
minj
w
pfv
loop
col
17
Recirculation Concept
Control Problem
Figure 4. Basic concepts for direct solar steam generation in
parabolic trough collectors. In the once-through mode, water
is directly converted into superheated steam in the collector
row. In the injection mode, water is injected at several places
along the collector row. In the recirculation mode, there is a
water-steam separator placed in the middle of the row.
18
April 2004
interactions, the SISO transfer functions of all relevant control loops (Table 3) were experimentally investigated for
the three different operating points defined in Table 2. System identification was used to estimate open-loop process
parameters such as gains, deadtimes, and time constants
that experimentally fit step response data. Based on the
The PI output is calculated using a classical interactive controller. The transfer function of the controller has the form output = K (1 + 1/Ti s)error.
Model
G(s) =
s2
0.1375
+ 1.322s + 0.3329
3.2 104
s + 0.2
a cs
G 1 (s) =
e
s+b
10
5.3 %/bar
184
0.0015 kg/s/ C
600
500%/kg/s
8 105 kg/s/ C
12
250
April 2004
1.1%/bar
Ti [s]
Outlet steam
temperature control via
feed valve (G1 master
loop, G2 slave loop)
Kp
3 102
s + 0.1
20% kg/s
12
19
Feed pump control loop: The rotational speed of the feed pump is
adjusted by a PI controller to maintain a specific
pressure drop in the feed valve, creating a flow in
steady state that is directly proportional to the valve
FC
TC
FT
TT
PC
PT
FT
LT
Final
Steam Separator
LC
Injection Line
Superheated Steam
FC
POT
Flash
Tank
Feed Pump
PDC
Feedwater Tank
Air Condenser
Equivalent
Turbine
Load
H.P. Steam
Vapor Feed
Feed
Preheater
L.P.
Legend
TT - Temperature Transmitter
FT - Flow Transmitter
PT - Pressure Transmitter
PDT - Pressure Drop Transmitter
LT - Level Transmitter
Figure 5. Diagram of the DISS test loop configured in the once-through mode. Four control loops comprise the
implemented control scheme. Although outlet steam pressure and temperature loops are the main control loops, there is an
additional controller for maintaining a constant pressure drop in the feed valve.
20
April 2004
TT
PC
PT
LC
LT
Middle
Steam
Separator
TC
FC
Recirculation
Pump
Final
Steam Separator
LC
Injection Line
Superheated Steam
LT
FT
Flash
Tank
Feed
Valve
Feed Pump
PDT
PDC
Feedwater Tank
Air Condenser
Legend
TT - Temperature Transmitter
FT - Flow Transmitter
PT - Pressure Transmitter
PDT - Pressure Drop Transmitter
LT - Level Transmitter
Equivalent
Turbine
Load
H.P. Steam
Vapor Feed
Feed
Preheater
L.P.
Figure 6. Diagram of the DISS test loop configured in the recirculation mode. Five control loops comprise the
implemented control scheme. Although outlet steam pressure and temperature loops are the main control loops, there are
three additional controllers for settling the recirculation water flow, the pressure drop in the feed valve, and the liquid level in
the middle separator.
opening. The feed pump control loop, therefore, provides a linearized flow relationship between valve
position and flow for PI control.
April 2004
21
related to the uncertainty of the models obtained. Depending on the operating conditions (outlet steam flow production, temperature, pressure, and solar radiation available),
the gain, time constants, and time delays vary. The different model parameters influence the PI control design.
Therefore, once a set of PI parameters is chosen, closedloop simulations are performed by varying the model parameters to guarantee wide stability margins for the whole
range of model parameters. Consequently, the selection of
the PI parameters is conservative. The detailed schemes
are discussed in the following subsections.
Although interactions between loops exist, they are
small because the two slave loops, which are fast compared to the other loops, are able to reject slow disturbances due to the interactions caused by other loops.
The outlet steam pressure loop is also faster due to a
smaller time constant and no dead time and is thus able
to reject the disturbances coming from the slower temperature loops. Also, the temperature loops have an
inherent interaction reduction mechanism. As a result,
the interactions are canceled by the control strategy
E
Tin
Tamb
Tinj
minj_set
Feedforward
Controller
FFFV
Tref
eT
PI
mff
Tout
min_dem
em_in
PI
Anti-Windup
afv
Plant
min
meT
Figure 7. Outlet steam temperature control based on forward action by means of a feed valve. The outer loop of the cascade
structure consists of a feedforward controller, which dictates the nominal feedwater flow, in parallel with a PI controller. The
inner control loop is a PI controller with antiwindup action.
Pressure [bar]
30
60
100
22
Phase
Temperature [ C]
a1
a2
R-square
Standard
Deviation [kJ/kg]
Water
Steam
Water
Steam
Water
Steam
21
+2225
34
+1940
54
+1480
4.38
2.54
4.48
3.12
4.61
4.10
0.99989
0.99868
0.99965
0.99686
0.99905
0.99415
3
7
7
11
12
15
< 234
< 400
< 276
< 400
< 312
< 400
April 2004
Feedforward
Control of Outlet
Steam Temperature
b1
b2
b3
0.687257
1.433242
2.895474
0.00194
0.00566
0.01640
0.000026
0.000046
0.000065
oscillations.
collected
in
out
To manage these instabilities, the outlet steam temperature control loop is a mixed cascade-feedforward control The collected energy is corrected using an estimated effiloop (Figure 7) aimed at guaranteeing a desired flow in the ciency factor that implicitly considers the optical efficienface of valve nonlinearities and changes in disturbances cy and, consequently, the optical losses. The simplified
affecting the loop (see Figure 7 and Nomenclature). The energy balance equation can be written as
feedforward term uses a process model to effect changes
(min + minj )hout (minhin + minjhinj ) =
in the controller output in response to measured changes
in the load before errors occur. The outer loop is comloop Acol Lloop E Ul S abs (Tav Tamb ).
posed of a feedforward function FFFV in parallel with a PI
controller with fixed parameters. Block FFFV calculates a In this equation, the specific enthalpy hout at the outlet is
nominal flow mff , and the parallel PI controller corrects replaced by the outlet enthalpy reference href , and the
this value according to the current output Tout . In a set- water flow rate minj injected in the last collector is
point change, this PI controller uses only integral action replaced by the nominal injection flow minj set established
because the new temperature reference also passes to the in the temperature control loop by means of the injector
FFFV block that calculates the nominal flow mff . The flow valve to avoid feeding back variations (that could be oscilmin dem calculated by this master loop is the input to the latory) dictated by the temperature control loop by means
inner slave PI control loop, which calculates a new aper- of the injector valve in the block FFFV . Such feedback deteture af v of the feed valve. The saturation included in front riorates the temperature response. Considering these subof the PI inner control loop limits the inlet water flow to a stitutions, the feedforward control equation used to
minimum value of 0.3 kg/s; this limitation guarantees tur- calculate the nominal feedwater flow mff to achieve the
bulent flow in the absorber pipes and consequently con- desired outlet temperature Tref is given by
strains the temperature gradients in the cross-sectional
mff =
area of the pipes that should be less than 50 C, which is a
loop Acol Lloop E Ul S abs (Tav Tamb )minj set (href hinj ) ,
temperature gradient limit from the point of view of the
href hin
pipe thermal stress.
April 2004
23
Tin_c
min_c
Tinj
minj_set
Feedforward m
ff_iv
Controller
FFIV
Tref
eT
PI
Tout
minj
minj_dem
PI
Antiwindup
aiv
Plant
minj
meT
Figure 8. Outlet steam temperature control based on feedforward action by means of an injector. The nominal injection flow
is dictated manually when the controller is operating in automatic mode. This nominal value is corrected by the output of the
outer loop of the cascade structure, which consists of a feedforward controller in parallel with a PI controller. The inner control loop is based on a PI controller with antiwindup action.
[kJ/kg],
where a1 and a2 are coefficients estimated by linear regression using the enthalpies and temperature values in thermodynamic tables [10] (Table 4). Ul is a factor related to
the thermal losses, which for an LS-3 type collector can be
approximated by [11]
Ul = b1 + b2 (Tav Tamb ) + b3 (Tav Tamb )2 ,
where b1 , b2 , and b3 depend on the average temperature of
the fluid in the absorber pipes (Table 5). To simplify the
control-loop structure, the average temperature Tav of the
fluid in the field is approximated by a constant value for the
three different operating points. Values based on inlet and
outlet conditions and conditions in the preheating, evaporation, and superheating sections are listed in Table 6.
24
April 2004
50
40
30
20
10
0.8
240
0.7
210
0.6
180
0.5
150
0.4
Outlet Steam Temperature
Set Point
Inlet Water Flow - Feed Valve (Control Signal)
Injection Water Flow - Injector (Control Signal)
120
10
11
12
13
Local Time
(a)
14
15
35
16
0.0
0.9
800
0.8
700
0.7
600
0.6
500
0.5
400
0.4
300
0.3
32
15
24
10
16
0
16
15
15
900
20
14
14
64
40
12
13
Local Time
(c)
12
13
Local Time
(b)
0.1
1.0
25
11
11
0.2
1,000
48
10
10
0.3
72
56
30
09
30
09
0
16
45
40
60
09
Pressure [bar]
0.9
270
90
Aperture [%]
Pressure [bar]
1.0
300
Flow [kg/s]
60
Power [%]
330
Flow [kg/s]
70
Temperature [C]
0.2
200
Direct Solar Irradiance
Outlet Steam Flow
100
0
09
10
11
0.1
12
13
Local Time
(d)
14
15
16
0.0
Figure 9. Control loop responses during operation at 30 bar (22 April 2002): (a) includes the feed pump control loop
response, and (b) includes the temperature control loop response; (c) includes the outlet pressure control loop response, while
(d) includes the available radiation and generated steam flow.
30 bar
irradiance1
[650, 1000]
[0.40, 0.60]
[0.35, 0.70]
[280, 320]
[250, 310]
[180, 215]
Direct solar
Global collector efficiency1
Collector inlet mass flow
Outlet temperature reference
Collector inlet fluid temperature
Injection water temperature
1 Changes
60 bar
W/m2
[650, 1000]
[0.40, 0.60]
[0.350.70]
[320, 370]
[290, 370]
[220, 260]
kg/s
C
C
C
100 bar
W/m2
kg/s
C
C
C
[650, 1000]
[0.40, 0.60]
[0.35, 0.70]
[340, 400]
[330, 390]
[260, 300]
W/m2
kg/s
C
C
C
Table 8. Outlet steam temperature control with injector valve: FFIV parameters.
Outlet Steam
Pressure [bar]
c1
c2
c3
c4
c5
R-square
Standard
Deviation [kg/s]
30
6.212 104
0.00313
1.7 106
3.0 106
0.00171
0.95035
0.00112
60
104
0.00505
4.4
106
106
0.00279
0.95219
0.00146
8.942 104
0.00494
4.2 106
5.8 106
0.00261
0.95167
0.00117
100
April 2004
8.457
7.1
25
flow rate dictated from the injector valve, since zero flow
rate would deteriorate the control action due to the nonlinearity of the injector when this actuator is nearly closed,
as was observed in real tests.
The PI parameters of the outer and inner loops were
also calculated from open-loop responses using the
process reaction method. Linearized models detailed in
Table 3 were used to simulate the closed-loop responses
and study the stability margins in the worst cases for the
model uncertainty. The final selection of values for the PI
parameters was made in a conservative way to avoid instability in the system and to diminish interaction with the
rest of controllers [8].
The feedforward action formulated for the feed valve
control loop is obtained from a simplified steady-state
energy balance formulation for the collector given by
40
30
20
10
Power [%]
Pressure [bar]
50
10
11
12
13
Local Time
(a)
14
45
330
1.0
300
0.9
270
0.8
240
0.7
210
0.6
180
0.5
0.4
150
Outlet Steam Temperature
Set Point
120
90
30
15
0.3
60
0
09
60
09
10
11
12
13
Local Time
(b)
Flow [kg/s]
Set Point
(min
70
Temperature [C]
Energy
Enthalpy
Enthalpy
{Losses}.
=
collected
in
out
14
0.2
0.1
0.0
15
72
1,000
1.0
64
900
0.9
56
800
0.8
700
0.7
600
0.6
500
0.5
400
0.4
30
48
35
Set Point
Aperture [%]
Pressure [bar]
40
25
40
20
32
15
24
10
16
100
0
15
0
09
10
11
12
13
Local Time
(c)
14
300
Flow [kg/s]
0.3
200
0.2
0.1
09
10
11
12
13
Local Time
(d)
14
0.0
15
Figure 10. Control loop responses during operation at 30 bar (26 April 2002): (a) includes the feed pump control loop
response, (b) includes the temperature control loops response, (c) includes the outlet pressure control loop response, and (d)
includes the available radiation and generated steam flow.
26
April 2004
Using this equation, thermodynamic tables [10] for calculating the enthalpies corresponding to each temperature
and pressure, and data obtained using the data series
detailed in Table 7, a regression analysis was performed to
obtain the feedforward function for calculating the injection flow rate correction. The multiple regression model
has the form
mff
iv
April 2004
27
70
330
0.9
300
0.8
270
0.7
240
0.6
210
0.5
60
50
40
30
20
Pressure Drop Across Feed Valve
Set Point
Feed Pump Power (Control Signal)
1
0
09
10
90
Pressure [Bar]
80
70
12
13
Local Time
(a)
14
15
90
60
09
14
15
16
1.0
0.8
700
0.7
600
0.6
500
0.5
400
0.4
300
0.3
20
10
4
0
15
12
13
Local Time
(b)
0.9
12
14
11
800
30
12
13
Local Time
(c)
0
10
32
16
11
0.1
900
20
10
0.2
1,000
40
0
09
0.3
36
24
50
120
10
28
60
150
16
0.4
180
0.2
200
Direct Solar Radiance
Outlet Steam Flow
100
0
09
Flow [kg/s]
Flow [kg/s]
1.0
Temperature [C]
360
Power [%]
80
Aperture [%]
Pressure [Bar]
0.1
0
10
11
12
13
Local Time
(d)
14
15
16
Figure 11. Control loop responses during operation at 60 bar (17 July 2002). (a) includes the feed pump control loop
response, (b) includes the temperature control loops response, (c) includes the outlet pressure control loop response, and (d)
includes the available radiation and generated steam flow.
case, null values of inlet mass flow led to zero production, which is commercially undesirable). In this transient situation, a mixed steam/water flow feeds the
separator tank where it condenses, returning to the feed
water through the separator drain valve, increasing the
parasitic load of the system as well as security. A control system configured to operate the plant with zero
inlet flow would have to satisfy stringent specifications,
mostly under actuator saturation. Such operation would
require that all the collectors be defocused to avoid
dangerous conditions in the solar field.
Conclusions
The DISS project demonstrated that it is possible to produce high-pressure, high-temperature steam directly in
parabolic trough solar collectors. A leading plant using
solar technology has been operated in two different
modes. This article describes the once-through mode,
28
April 2004
Acknowledgments
We thank the European Commission for support of the second phase of the DISS project (contract JOR3-CT98-0277)
within the framework of the E.U. JOULE Program. We
would also thank MCYT for funding this work under grants
DPI2002-04375, DPI2001-2380, and QUI99-0663. We thank
the anonymous reviewers for their helpful comments that
improved the article.
References
[1] E.F. Camacho, M. Berenguel, and F.R. Rubio, Advanced Control of
Solar Plants. London: Springer-Verlag, 1997.
[2] G. Cohen and D. Kearney, Current experiences with SEGS parabolic trough plants, in Proc. 8th Int. Symp. Solar Thermal Concentrating
Technologies, Kln, Germany, 1996, pp. 217244.
[3] E. Zarza, L. Valenzuela, J. Len, D. Weyers, M. Eickhoff, M. Eck, and
K. Hennecke, The DISS project: Direct steam generation in parabolic
trough systems. Operation & maintenance experience and update on
project status, J. Solar Energy Eng., vol. 124, May 2002, pp. 126133.
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[5] University of Manchester (UMIST), Zentrum fr Sonnenergie- und
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under recirculation operation, submitted to Solar Energy J., 2002.
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[12] Composer Series. Electronic Documentation Symphony. Elsag
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April 2004
29