Abstract: Methods and apparatus for adjusting a spring load in an actuator are described. An example actuator includes a housing and a plate. Further, the example actuator includes one or more springs disposed in the housing to apply a force to the plate. Additionally, the example actuator includes a spring load adjuster having a collar extending through and movably engaged to the plate to enable an adjustment of the position of the collar relative to the plate to change a load provided by the one or more springs.

Abstract: A tripping control system for use with, for example, turbines, includes a block circuit having two or more redundant blocking valves disposed or connected in series within a pressure supply line to block the supply of hydraulic fluid within the pressure supply line and a bleed circuit having two or more bleed valves connected in parallel between the pressure supply line and a return or dump line to bleed to the hydraulic fluid from the pressure supply line. The blocking valves and the bleed valves are actuated by one or more control valves under the control of a process or safety controller which trips the turbine by first performing a bleed function using the bleed valves, which then causes the block function to automatically actuate. Pressure sensors disposed at various locations in the tripping control system provide feedback to the controller to enable the controller to test each of the block and bleed valves individually, during operation of the turbine, without causing an actual trip of the turbine.

Abstract: An integrated optimization and control technique performs process control and optimization using stochastic optimization similar to that used in biological immune systems during on-line operation of a process, the technique collects and stores indications of process control states. During steady-state operation, the technique optimizes process operation by developing sets of process control inputs from stored process control states using an objective function that defines an optimality criterion. Moreover, after one or more disturbance inputs experiences a significant change, the technique responds by comparing the changed disturbance inputs to the disturbance inputs of at least some of the stored process control states to determine the stored process control states that are closest to the new process operating condition.

Abstract: A method of controlling a power generating unit or other process equipment with a slow reaction time includes creating a feedforward control signal to selectively include a fast response rate component or a slow response rate component based on the average rate at which a load demand set point signal has changed during a particular previous period of time. The method then uses the developed feedforward control signal to control the power generating equipment or other slowly reacting process equipment. In particular, a control method switches between introducing a fast or a slow response component within a feedforward control signal based on whether the change in the load demand set point over a particular period of time in the past (e.g., an average rate of change of the load demand set point signal) is greater than or less than a predetermined threshold. This method is capable of providing a relatively fast control action even if the expected load demand set point change is in a small range.

Abstract: A two-stage model predictive control (MPC) controller uses a process model and two separate MPC control modules, including a feedfoward MPC control module and a feedback MPC control module, to determine a set of control signals for use in controlling a process. The feedforward MPC control module uses the process model to determine a feedforward control component for each of a set of control signals and the feedback MPC control module uses the process model and one or more measured process outputs to determine a feedback control component for each of the set of control signals. The two-stage MPC controller combines the feedforward control components with the feedback control components to form the final control signals used to control the process.

Abstract: The disclosure is directed to a saturated water spraying system configured to rapidly respond to rapid load changes by implementing a single integrated DCS control block. The integrate DCS control block may include a plurality of process control routines that are necessary to control the operation of the spraying system. For example, upstream and downstream PID control routines may determine and output control variables, and other control routines may be provided as necessary to handle disturbances within a boiler affecting the outlet and spray steam temperatures, and to ensure that the steam temperatures do not fall into the saturation region during operation of the boiler. Because the routines are part of the same control block, the common storage for the control block may be accessed by each of the routines without the necessity of establishing additional communication links for transferring the information as is required when using cascaded function blocks.

Abstract: A method of controlling a power generating unit or other process equipment with a slow reaction time includes creating a feedforward control signal to selectively include a fast response rate component or a slow response rate component based on the average rate at which a load demand set point signal has changed during a particular previous period of time. The method then uses the developed feedforward control signal to control the power generating equipment or other slowly reacting process equipment. In particular, a control method switches between introducing a fast or a slow response component within a feedforward control signal based on whether the change in the load demand set point over a particular period of time in the past (e.g., an average rate of change of the load demand set point signal) is greater than or less than a predetermined threshold. This method is capable of providing a relatively fast control action even if the expected load demand set point change is in a small range.

Abstract: A method of controlling soot blowers near a heat exchange section includes generating models of both the ideal clean operating condition of the section and the dirty operating condition. The current operating condition of the section is used to calculate a reliability parameter that provides an indication of the reliability of the ideal and dirty models. If the reliability parameter indicates that the models are reliable, the models are used to help evaluate the cleanliness status of a particular heat exchange section and assist in making decisions on whether to blow the section or not, and whether to make any necessary adjustments to the operating sequence of the soot blowers. If the reliability parameter indicates that the models are unreliable, the models are regenerated using additional process data.

Abstract: An isolating manifold fluidly connected between a hydraulic valve and a hydraulic manifold operates to automatically isolate the valve from the hydraulic manifold as the valve is removed from the manifold, without requiring any particular blocking and bleeding procedures to be implemented on the valve or the manifold prior to the removal process. The isolating manifold includes an adaptor removably mounted onto a base with various pressure, control and tank fluid channels disposed in alignment through the adaptor and base portions to allow fluid to flow through each of the channels between the hydraulic manifold and the valve. During operation, the valve is mounted onto the adaptor while the base is mounted onto the hydraulic manifold.

Abstract: A technique of implementing performance monitoring in a power plant is appropriate to control operating parameters and factors connected with the efficiency of the energy production process in an energy marketplace that is more complex than in the past, and that takes into account more than just the cost of fuel. In particular, this method works well when the real costs of production are dependent on other variable costs besides the cost of fuel, such as environmental credits, equipment degradation and repair costs, as well as electrical energy trade market factors like ramp rate, LMP factors, and the ability to deliver contracted power levels and spot transactions. The power plant performance monitoring technique applies a statistical analysis to collected power plant data to determine the factors that are best controlled or changed to affect (increase) the efficiency or other primary performance indication of the plant, in whatever state or operating level the plant is run.

Abstract: An economic dispatch program optimally allocates load demand specifying real power and reactive power to be generated by a power plant among various power generators in a manner so that each of the power generators are operated within its optimal operating space as defined by a reactive capability curve. Allocating a power demand with consideration of the reactive capability curves of the power generators results in optimal generation of real power and reactive power as specified by the load demand. Alternatively, the economic dispatch program allocates load demand specifying real power and reactive power to be delivered by a power grid among various power plants wherein one or more of the various power plants have capacity limits exhibited by reactive capability curves.

Abstract: A technique of controlling a boiler system such as that used in a power generation plant includes using manipulated variables associated with or control inputs to a reheater section of the boiler system to control the operation of the furnace, and in particular to control the fuel/air mixture provided to the furnace or the fuel to feedwater ratio used in the furnace or boiler. In the case of a once-through boiler type of boiler system, using the burner tilt position, damper position or reheater spray amount to control the fuel/air mixture or the fuel to feedwater flow ratio of the system provides better unit operational efficiency.

Abstract: A statistical performance evaluation system for a thermodynamic device and process uses the achievable performance derived from statistics and real-time data for the device or process to evaluate the current performance of the device or process, and to adjust the operations of the device or process accordingly, or provide feedback to an operator or other monitoring system for taking corrective actions to obtain performance approaching the optimum achievable performance. The achievable performance of the device or process is derived from data collected during operational periods when the best achievable performance is anticipated, such as after maintenance is performed, and supersedes the ideal or design performance specified by the manufacturer, which typically does not represent the actual operating conditions in the field, as the basis for evaluating the real-time performance of the device.

Abstract: A statistical process control system employs a consistent soot blowing operation for a heat exchange section of, for example, a fuel burning boiler, collects heat absorption data for the heat exchange section and analyzes the distribution of the heat absorption data as well as various parameters of the heat absorption distribution to readjust the soot blowing operation. The statistical process control system may set a desired lower heat absorption limit and a desired upper heat absorption limit and compare them, respectively, with an actual lower heat absorption limit and an actual upper heat absorption limit to determine the readjustment to be made to the soot blowing operation. Alternatively, the statistical process control system may be used to determine permanent slagging of the heat exchange section.

Abstract: A system for generating updated reactive capability curves of a generator operates the genarator at a number of operating load levels and at a number of different power factors to collect data regarding the real and reactive power generated at each of the various operating load levels and power factors. Subsequently, the system analyzes the collected data to determine an actual reactive capability curve of the generator. The system also provides generator health monitoring and identifies changes and trends in the capability curves of the generator. The updated reactive capability curves may be used by an economic dispatch program in determining optimum MW and MVAR setpoints for the generator.

Abstract: An integrated optimization and control technique performs process control and optimization using stochastic optimization similar to the manner in which biological immune systems work, and thus without the use of historical process models that must be created prior to placing the control and optimization routine in operation within a plant. In particular, an integrated optimization and control technique collects various indications of process control states during the on-line operation of the process, and stores these process control states within a memory. During steady-state operation of the process, the integrated optimization and control technique attempts to optimize the process operation by developing a series of sets of process control inputs to be provided to the process, wherein the series of process control inputs may be developed from the stored process control states using an objective function that defines a particular optimality criteria to be used in optimizing the operation of the process.

Abstract: The disclosure is directed to a saturated water spraying system configured to rapidly respond to rapid load changes by implementing a single integrated DCS control block. The integrate DCS control block may include a plurality of process control routines that are necessary to control the operation of the spraying system. For example, upstream and downstream PID control routines may determine and output control variables, and other control routines may be provided as necessary to handle disturbances within a boiler affecting the outlet and spray steam temperatures, and to ensure that the steam temperatures do not fall into the saturation region during operation of the boiler. Because the routines are part of the same control block, the common storage for the control block may be accessed by each of the routines without the necessity of establishing additional communication links for transferring the information as is required when using cascaded function blocks.

Abstract: A process control system simulation technique performs real-time simulation of an actual process control network as that network is running within a process plant in a manner that is synchronized with the operation of the actual process control network. This real-time, synchronized simulation system includes a simulation process control network and a process model which are automatically updated periodically during the operation of the actual process control network to reflect changes made to the process control network, as well as to account for changes in the plant itself, i.e., changes which require an updated process model. The disclosed simulation system provides for more readily accessible and usable simulation activities, as the process control network and the process models used within the simulation system are synchronized with and up-to-date with respect to the current process operating conditions.

Abstract: A statistical process control system employs a consistent soot blowing operation for a heat exchange section of, for example, a fuel burning boiler, collects heat absorption data for the heat exchange section and analyzes the distribution of the heat absorption data as well as various parameters of the heat absorption distribution to readjust the soot blowing operation. The statistical process control system may set a desired lower heat absorption limit and a desired upper heat absorption limit and compare them, respectively, with an actual lower heat absorption limit and an actual upper heat absorption limit to determine the readjustment to be made to the soot blowing operation. Alternatively, the statistical process control system may be used to determine permanent slagging of the heat exchange section.

Abstract: An economic dispatch program optimally allocates load demand specifying real power and reactive power to be generated by a power plant among various power generators in a manner so that each of the power generators are operated within its optimal operating space as defined by a reactive capability curve. Allocating a power demand with consideration of the reactive capability curves of the power generators results in optimal generation of real power and reactive power as specified by the load demand. Alternatively, the economic dispatch program allocates load demand specifying real power and reactive power to be delivered by a power grid among various power plants wherein one or more of the various power plants have capacity limits exhibited by reactive capability curves.