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Control Method Development Platform for Hybrid Power Plants

Conference Paper · June 2016

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 Control Method Development Platform for
Hybrid Power Plants
Hannu Mikkonen, Suvi Suojanen, Elina
Hakkarainen, Mikko Jegoroff

VTT Technical Research Centre of Finland

Box 1603, 40101 Jyväskylä, Finland
(Tel: +358405953909; e-mail: Hannu.i.Mikkonen@vtt.fi, Suvi.Suojanen@vtt.fi,
Elina.Hakkarainen@vtt.fi and Mikko.Jegoroff@vtt.fi)

Abstract: As the share of intermittent solar and wind power increases in the energy systems, the role and
operation of the conventional power plants has to change from base load power plants to balancing power
plants in order to balance the grid and maintain their profitability. Due to cyclic and intermittent character of
solar and wind energy, the control responses of existing boilers must be faster in order to achieve optimal
controllability and load-following energy production. Simultaneously, the tightened fuel flexibility
requirements and reduced emission limits have to be taken into account.

In the future, the utilisation of hybrid power plants in which a renewable energy source is integrated to a
conventional power plant increases due to their environmental friendliness, balancing capability and
domestic character. The new hybrid combinations will also need new effective methods to allow flexible
operation and reliable control of the power plant. Time dependent modelling platform has been developed in
Apros in order to analyse the performance of different integrated plant layouts. The platform offers tools and
methods to analyse and further improve interactions between intermittent renewable energy sources and
traditional power plants but also methods, controls and optimisation strategies for hybrid power plant
concepts.

The application that has been recently developed at VTT to Apros Combustion simulation tool is a model for
integration of concentrated solar power (CSP) into bubbling fluidized bed (BFB) power plant. The model is
used to analyse the performance of a novel solar boosted power plant concept and its control strategies. The
platform also points out a cost effective way to increase renewable solar energy combined with maximal
utilisation of existing power plant infrastructure and electricity network. The hybrid plant studied includes a
BFB -power plant producing 134 MWe electricity and a solar field. The dynamic simulations conducted with
the BFB-boiler power plant and the whole process integrate showed that the developed platform offers a
valuable tool for hybrid power plant development and optimisation. Based on the results of simulation test
responses, controls and process phenomena are analysed and concluded to work realistic.

Keywords: Apros, BFB, CSP, simulation, control, hybrid power plant

Table of Contents
1. Introduction ......................................................................................................................................... 3
2. Hybrid power plants ............................................................................................................................. 4
2.1 Conventional steam power plants and bubbling fluidized bed combustion ................................. 4
2.2 Concentrated solar power (CSP) ............................................................................................... 5
2.3 Integrated power production: Hybrid power plants .................................................................... 7
3. Simulation tool..................................................................................................................................... 8
3.1 Features of Apros ............................................................................................................................... 8
3.1.1 Comprehensive process model libraries ....................................................................................... 8
3.1.2 Easy model definition .................................................................................................................. 9
3.1.3 Solution based on physical modelling .........................................................................................10
3.1.4 Both simple and high fidelity models ..........................................................................................10
3.1.5 Testing and training simulator features .......................................................................................10
4. Model construction .............................................................................................................................11
4.1 Simulation model ........................................................................................................................11
4.2 Automation .................................................................................................................................12
4.2.1 The boiler controls ...............................................................................................................13
4.2.2 The solar field control ..........................................................................................................14
5. Simulation results................................................................................................................................14
6. Conclusion ..........................................................................................................................................19
 1. Introduction
The share of the renewable energy has already increased drastically. The role and operation of these types of
power plants will change and solutions need to be developed to match the traditional energy production
infrastructure with new intermittent distributed energy production, simultaneously accounting for the
continuously increasing volatility on the demand side.

At VTT, a time dependent modelling platform has been developed for analysis of integrated power plant
models in a dynamic simulation environment. In the development, the exceptionally fast, globally unique
tools for fluidized beds, developed at VTT, will be used to produce new tools for integrated modelling. The
main process units and streams, the control system and supporting calculations that are essentially required
to operate the system will be included in Apros modelling.

The purpose of the hybrid power plant is to generate the targeted amount of steam in sufficient pressure and
temperature range for electricity production. In the hybrid concept, the solar field produces superheated
steam for the joint steam cycle, whereas the conventional steam power plant guarantees continuous stable
electricity production with correct steam parameters. The operation of the hybrid power plant is monitored
and controlled with a basic control system. Effective implementation and operation of the control system
requires extensive knowledge of the process in advance.

The purpose of this work was to provide new information about the behaviour of the flexible integrated
energy systems, and by this means, develop the boiler operation for the hybrid system conditions. In this
paper, the interactions between the CSP field and conventional steam power plant are analysed in addition to
operation strategies for hybrid power plant concepts. As a result, the simulations include typical operation
transients of one hybrid concept over one day and with peak load of solar field to verify the operability of the
novel hybrid concept and its control strategies from low level to upper level controllers.
 2. Hybrid power plants
2.1 Conventional steam power plants and bubbling fluidized bed combustion

A typical conventional steam power plant is a subcritical unit, in which live steam parameters are
160-180 bar and 535-565 °C and the net efficiency is between 33 to 39 % based on lower heating value
(LHV) of the fuel [1]. The electricity generation is based on a regenerative and reheated Rankine cycle
process (Figure 1). On any steam power plant, the feed water is preheated in the low pressure (LP) and high
pressure (HP) feedwater heaters (FWH) by extracting steam from turbines. This improves the net efficiency
of the steam cycle, but reduces the power output of the plant. Typical subcritical steam boiler is a steam
drum boiler, which includes furnace, economizer, water tubes, steam drum, superheaters and reheater. Fuel is
combusted in the furnace with excess air and part of the feedwater is evaporated in the water tubes. Saturated
steam is separated from water in the steam drum and the steam is superheated before the turbine in order to
avoid condensation in the turbine.

Figure 1. Schematic of conventional steam power plant with steam drum boiler.

Conventional steam power plants are being criticized due to their environmental impacts. In order to increase
the net efficiency and decrease pollution, greenhouse gases and fuel consumption rates, steam parameters of
the conventional power plants are increased and combustion process is improved [2]. One of the improved
combustion technologies is bubbling fluidized bed (BFB) combustion, which benefits are in situ reduction of
sulphur dioxide (SO2) emissions, fuel flexibility and low nitrogen oxide (NOx) emissions [2,3]. The fuel is
fed into the furnace, which contains limestone and inert bed material, such as sand or ash. The fuel, bed
material and limestone are fluidized by combustion air, which is distributed throughout the furnace floor.
BFB refers to low fluidizing velocity in the bed, which prevents solids to carry over from the furnace into the
convective passes. In BFB boiler, the fuel particle size is 0-50 mm and the fluidizing velocity is 1-3 m/s [3].
The bed material functions as disperser for the incoming fuel, stores a large amount of thermal energy and
heats the fuel quickly to its ignition temperature. The limestone of bed material acts as a sorbent for SO2.
Due to the effective mixing and turbulence of the fluidized bed, heat transfer to the bed material is enhanced,
and the generation of heat is lower and more evenly distributed than in pulverized combustion. Thus, the
furnace temperature of a typical BFB boiler is about 780-900 °C, which is well below the temperature range
where thermally induced NO x production occurs. The thermally induced NOx begins to form when the
maximum temperature level of the boiler reaches 1,300 °C. Furthermore, by staging the combustion air to
different air zones, the formation of fuel-bound NOx can be minimized.
 2.2 Concentrated solar power (CSP)

Concentrated solar power represents one option to produce fully renewable energy. In 2014, the installed
CSP capacity was about 4 GW, most of the capacity located in Spain and U.S. By the end of 2015, global
deployment of the technology increased to 4.5 GW. IEA’s Technology Roadmap for Solar Thermal
Electricity foresees the capacity of 260 GW by 2030 and 980 GW by 2050. [4, 5] The prevailing and the
most mature CSP technology is parabolic trough collector (PTC) technology using synthetic oil as the heat
transfer fluid (HTF) [6]. Parabolic trough collector system together with Linear Fresnel collector (LFC)
system represents line focusing CSP technology. Both technologies track the sun along a single axis and
focus irradiance on a linear receiver. However, the receiver of the LFC is fixed, whereas the receiver of the
PTC moves together with the focusing device. [4] Temperature range of the parabolic trough power plant
using oil is limited under 400 C, restricting also the achievable efficiency. In order to achieve higher
temperatures, several other line focusing CSP concepts are under development or demonstration [6].
One potential concept is direct steam generation (DSG) in the solar field. The concept has several advantages
compared to oil-based system. The DSG solar field can achieve higher temperature range and efficiency, the
same water/steam fluid is circulated in the solar field and power block avoiding additional equipment, such
as heat exchangers, the pumping power consumption in the solar field is reduced, and water/steam do not
carry any environmental risk like oil. However, DSG technology imposes some challenges on the design of a
storage system since, besides sensible heat storage for preheating and superheating part, also storing heat at a
constant temperature for evaporation part is required. Several storage solutions have been researched,
making use of latent heat storage being one possible option. [6] Currently, there still does not exist
commercial solution for storage system integration to DSG solar field. The need for storage system can be
overcome by integrating solar field into a conventional power plant. In this system, the conventional part of
the integrated concept balances the power production of the solar field, thus providing load following power
from solar irradiance.
In the proposed concept, Linear Fresnel solar field (Figure 2) is integrated to a conventional power plant for
feedwater preheating at 340 C/40 bar. Parameters in this range are already in commercial use for the LFC
technology. For example, Novatec Solar’s Puerto Errado 2 (PE 2) power plant in Calasparra, Spain operates
at 270 C/55 bar [7]. Novatec Solar has also demonstrated production of superheated steam at a temperature
of about 500 C in its test facility Puerto Errado 1 (PE 1) in Calasparra, Spain. Direct steam generation in
parabolic trough collectors has been tested at the DISS facility at Plataforma Solar de Almeria, Spain with
steam parameters up to 500 C/110 bar. [6] Abengoa Solar has operated DSG solar field based on PTC
technology at 550 C/85 bar [8]. Also a commercial PTC solar power plant, TSE 1, is in operation in
Kanchanaburi, Thailand, producing superheated steam at 330 C/30 bar [9].

Figure 2. Schematic of Linear Fresnel collector [7].

Solar irradiance cannot be manipulated as traditional fuel used in power plants. The irradiance undergoes
both slow changes (daily cycle) and fast changes due to passing clouds. The main objective of the solar field
control system is to produce steam at constant temperature and pressure at the outlet of the solar field in such
a way that the changes in the solar field inlet conditions and in the solar irradiance only affects the amount of
steam produced, but not its quality. The control of the DSG solar field differs from that of traditional solar
field using synthetic oil as HTF as both steam temperature and pressure has to be controlled instead of only
HTF temperature. [11]
Currently, three different operation modes are considered for the direct steam generating line focusing solar
field (Figure 3). With recirculation operation mode (a and b), water is preheated and evaporated in an
evaporator section. Steam quality at the evaporator inlet is typically between 60% and 80%. The two-phase
fluid flows into a separator. Water is recirculated back to the evaporator inlet, whereas the saturated steam is
send to the superheater section. The recirculation mode can be implemented both with a central steam drum
(a) and with distributed steam separators (b), of which the first option is applied in the proposed concept. The
central steam drum is shown to be more robust and efficient option. Both recirculation solar field variants
can have an additional injection in the superheater to stabilize the outlet temperature. In the once-through
operation mode, preheating, evaporation and superheating of the water/steam take place in a single collector
row without separation. The once-through mode offers potential for cost reduction with respect to
recirculation mode as steam drum, corresponding piping and recirculation pumps are not needed. However,
the outlet temperature control of the once-through solar field is more challenging. [6, 12]

Figure 3. Operation modes for direct steam generating line focusing solar field [3].
 2.3 Integrated power production: Hybrid power plants

Hybrid power plants can be used to produce more electricity with the same amount of fuel or to produce the
same amount of electricity with less fuel [13]. In other words, the hybrid system can be operated on power
boost mode or on fuel saving mode depending on the load demand. Both operation modes are applicable in
real-life conditions [14] and the benefits of the integration include, for example, lower installation costs and
levelized costs of electricity for CSP technology, decreased CO 2 emissions, wider suitable areas for CSP
applications, higher first and second thermodynamic law efficiencies compared to stand-alone CSP and
steam power plants and higher solar-to-electricity conversion efficiency [15,16]. Unlike stand-alone CSP
plants, CSP hybrid systems can generate dispatchable energy until cost-effective energy storage technology
for DSG systems is available [15].

The integration of CSP plant with steam power plant can already be achieved with a Linear Fresnel (LFC)
solar field with direct steam generation (DSG). In this configuration, solar steam is directly injected to the
steam cycle without additional cycle for heat transfer fluid and additional heat exchanger between the two
cycles. In addition, there is no need for energy storage equipment, if the fuel power of the steam boiler can
be adjusted within its operational limits to compensate the intermittency of solar irradiance. However, the
ease of the integration depends on the selected process arrangement and the development of flexible control
engineering for the hybrid system. The selected process arrangement of this paper is a feed water preheating
and turbine tap steam process arrangement [17, 18], in which superheated solar steam is fed to a turbine tap
steam line entering the last high pressure FWH (Figure 4). The extracted turbine tap steam from turbine is
replaced by solar steam. The steam parameters in this line are around 340 °C and 40 bar for subcritical units.
Solar steam can also be injected to other turbine tap steam lines if the solar field is capable of producing
steam at multiple enthalpy levels [16]. For perspective, the lowest steam parameters entering the lowest LP
FWH are approximately 65 °C and 0.26 bars. Regardless the process arrangement, the solar field has to
attain the steam parameters and mass flow rate of the turbine tap steam line [19].

Figure 4. Schematic of feedwater preheating process arrangement.

The feedwater preheating process arrangement allows updating the steam power plant without complex
integration with the steam boiler. In addition, the parallel operation of existing FWHs with the solar field
ensures the operation of the power plant at full capacity if disturbances occur in solar irradiance. However,
sophisticated control strategy needs to be developed in order to assure the parallel operation. Valuable work
can be obtained from both high temperature and low temperature applications, but the profit is much greater
in the substitution of HP FWHs than in substitution of LP FWHs [14,16, 17]. The maximum solar share in
the power boost mode is limited by the maximum load of the turbines and the capacities of FWHs. If all the
FWHs are replaced by solar steam, the turbines might not be able to operate on that load. On the contrary, in
the fuel saving mode, the maximum solar share is restricted by capacities of FWHs. Thus, the maximum
solar share in FWH process arrangement is approximately 20% if the solar field is capable of producing
steam with multiple enthalpy levels and all the FWHs are replaced [18].

3. Simulation tool
Apros is a simulation software for full-scale modelling and dynamic simulation of industrial processes e.g.
combustion power plants, nuclear power plants, paper manufacturing processes and distributed renewable
energy systems. Apros allows to model gas/liquid flow networks, automation and electrical systems. The
Apros simulation engine contains versatile solvers and model libraries. The design user interface,
Apros Modeller Interface, is built on the Simantics platform, and it provides an easy on-line access for
configuring and running simulation models.

Apros supports the use of dynamic simulation in all phases during the life span of the process, avoiding
unnecessary data transfer and reconfiguration of the simulation model e.g. Apros simulation environment
enables the use of engineering simulator as a basis for a training simulator. Once the simulation model is
completed in the design phase it can be re-used with DCS (Distributed Control System) as a checkout and
training tool (Figure 5).

Figure 5. Dynamic simulation is a powerful tool throughout the complete life cycle of a plant: from
pre-design to maintenance.

3.1 Features of Apros

3.1.1 Comprehensive process model libraries

The user has access to a set of predefined and validated process component models that are conceptually
one-to-one analogous with concrete devices (pumps, valves, tanks etc.) and hide all solution algorithms. The
user only needs to select appropriate process components from model libraries, connect them together, and
enter the process related input data.
The Apros database structure supports hierarchical model description. Normally, the user operates on the
component level using predefined process components such as pipes, valves, heat exchangers, vessels, etc.,
which automatically generate the calculation level objects (nodes and branches).

3.1.2 Easy model definition

The simulation model is configured graphically through Apros Modeller Interface, a CAD-like user
interface by drawing diagrams and filling in dialogs of component properties. Apros Modeller
Interface includes a diagram editor view and additional views to edit parameter values, define trend charts
etc. It is used along with the property view for defining the process to be simulated and for modifying it. For
simulation control there is another view. The model can be divided into several diagrams by using
connection flags. Re-usable model configurations can be packaged into structural components and typicals.
The number of diagrams in a process model is not limited. An example of Apros folder tree is presented in
the Figure 6.

The configuration changes are passed to the simulation engine on-line, and the simulation can continue
straight after the change. At any time, the state can be saved into a named Initial Condition and at any time,
the user can revert to an Initial Condition saved previously. The complete model, or parts of a model, can be
exported or imported. This enables the re-use of models between projects and the storing of models in
libraries for future use.

Figure 6. Typically a simulation model contains a large number of diagrams organized in a folder tree.

In addition to model configuration and modification, Apros Modeller Interface provides tools for managing
simulation experiments, and for monitoring the dynamic behaviour of the simulation model either as
numerical values (monitors, according to profiles) or as trend graphs. Typically one graph shows the long-
term behaviour of the system, while the monitors provide instantaneous values of each component's most
essential properties. Naturally, also the on-line graphs can be printed, in addition to which data can be logged
for post-processing. At simulation time, the graphical pictures can be used for changing component
properties on-line, e.g. set point values, controller parameters and even process component dimensions. The
logic connections in the automation system can be automatically coloured according to their states.

The user needs not to be familiar with solution of differential equations nor any programming language. This
makes Apros a tool that is easy to use for process and control engineers not specialised in dynamic
modelling. Both the state and the structure of the model can be modified between and even during simulation
runs without any re-compilations. This promotes design productivity and impacts the quality of process and
control design throughout the design project.
3.1.3 Solution based on physical modelling

The thermohydraulics package of Apros is based on dynamic conservation equations of mass, energy,
momentum and component mass fractions. It provides means for solving of flows of furnish mixture, heat
conduction in solid structures and heat conduction between fluids and structures. In the solution of the
conservation equations, the model is considered as a network of nodes, i.e. control volumes, and branches,
i.e. connections between nodes. This network is managed automatically by the process component models,
which generate the calculation level components and deduce their attributes from the properties of the
process components, e.g. branch loss coefficients are solved by valve models. The primary state variables of
the thermohydraulic nodes are pressure, enthalpy, and component mass fractions, and for branches flow
velocity. Material property functions are used in calculating various quantities, such as density and viscosity,
according to pressure, enthalpy and component mass fractions.

The solution of the node and branch state variables is reduced to solving matrix equations. The equation
solver provides tools for solving large systems of linear equations arising from discretisation of partial
differential equations with respect to space and time. The modules and thermohydraulics in Apros have been
validated to a number of physical experiments to assure the accuracy also when used for design studies of
not yet existing plants.

3.1.4 Both simple and high fidelity models

The Apros model libraries provide models from simple to high fidelity; the level of fidelity may be selected
for each process component separately, and it can easily be changed later. That way one can create an
optimal model structure in respect of model fidelity and simulation speed. The speed of simulation is
important both in design and training simulators. In design simulators, the simulation speed should be clearly
faster than real time while still maintaining the necessary accuracy level. In training simulators, large plant
wide models must be simulated at least at real time. In some cases it may be advantageous to simulate faster
than real time e.g. if the training session includes slow phenomena and few operator actions are needed.

For the analysis simulator the speed requirement is not as strict. A more important feature is the accuracy of
simulation in the extreme values of process parameters encountered during start-up and emergency
conditions, and as consequences of process failures. The analysis simulator can be used for the design of
start-up and emergency procedures for the operators. By using very short time steps, very transient
phenomena can be studied by the aid of an Apros model. One may also let the time step vary based on
process conditions, which gives increased accuracy during the transient of interest.

3.1.5 Testing and training simulator features

Operator training is one of the primary applications of dynamic simulation, and also the reference list of
Apros includes several training simulators. Apros has a few advanced features to aid the development of
training simulators. For a training simulator, reduced snapshots may be used that only handle the dynamic
variables of the model. These are also cyclically stored in memory, allowing backtrack and, used in
combination with a time-stamped operator command log, replaying a scenario.

A lot of the process component models have predefined sets of malfunctions that can be triggered simply by
modifying the corresponding attribute value at simulation time. In addition, the developer of the training
session can create new malfunctions independent from the predefined ones, by using the generic malfunction
features. The interface of Apros enables rapid development of operator interfaces using any OPC compliant
control room emulation package in the Windows environment, e.g. ProcSee. Alternatively, the TCP/IP-based
low-level Apros Communication Library ACL can be used. Similar scenarios are interesting in operator
training and automation testing. For planning and executing automation tests, a specific product Apros
Testing Station is available [20].
 4. Model construction

4.1 Simulation model

The simulation model consists of the bubbling bed boiler, the turbine island and the Linear Fresnel solar
field. The boiler part includes fuel (coal), sand and limestone feeding systems, primary and secondary air
feeding systems with flue gas preheating, furnace (with convection and radiation heat exchange), flue gas
canal including all the gas to steam heat exchangers. The turbine island includes the main condenser,
condensate pumps, LP-preheating system with turbine taps, feed water tank, -pump and –valve, feed water
HP-preheating system with turbine taps and CSP steam preheating (one preheater), economiser, evaporator,
steam drum and the superheaters. The boiler model is separated in the gas side and the water/steam side. In
the Figure 7, part of the boiler model is illustrated.

Figure 7. The boiler model. On the left flue gas side and on the right water/steam side (the evaporator
and the drum).

In the Figure 8, part of the turbine island is illustrated.

Figure 8. The turbine island.

In the Figure 9. Linear Fresnel solar field.the Linear Fresnel solar field is illustrated. Each collector row has
the total length of over 760 meters and consists of 17 collectors: 15 in the evaporator section and two in the
superheater section. Four collector rows are set in parallel. Feed water parameters into the solar field are 10
bar/150 °C and produced steam parameters 40 bar/340 °C. The operation mode of the solar field is
recirculation mode, where the target steam mass fraction after the evaporator is 70%. Water is circulated
back to the solar field inlet, whereas the steam is fed into the superheating section. In the superheater, the
steam temperature is controlled by using spraying water valves. To avoid temporary pressure peaks during
the start-up phase of the solar field an additional recirculation line is used in the superheater section.
Detailed model description can be found in the article “Dynamic model development of linear Fresnel solar
field” [23].

Figure 9. Linear Fresnel solar field.

4.2 Automation
The main difference between a conventional power plant and a solar power plant is that the primary energy
source of solar field cannot be manipulated. The intensity of the solar radiation, in addition to its seasonal
and daily cyclical variations, also depends on atmospheric conditions such as cloud cover, humidity and air
transparency. This leads to significant variations in the dynamic characteristics of the field, such as the
response rate and the dead time, which cause difficulties in obtaining adequate performance over the
operating range with a fixed parameter controller. Thus this plant presents some characteristics that make it
difficult to control [21]:

Nonlinearity, complexity, requiring modelling simplifications, changing dynamics and changing

environmental conditions: (i) The solar radiation acts as a fast disturbance with respect to the
dominant time constant of the process; (ii) time varying input/output transport delay, since the delay
in action depends on the manipulated variable (steam flow rate); this type of delay appears both in
the field and in the pipe connecting the loops to the storage tank; (iii) when modelling
simplifications are done, there are strong unmodelled dynamics and the linearized dynamics vary
with the operating point; indeed, the plant is best modelled as a distributed parameter system and,
further, there are antiresonance modes (frequencies at which the magnitude of the frequency
response changes abruptly) in the frequency response of the collector field within the control
bandwidth, in such a way that when the system is excited with a signal (steam flow or solar
radiation) with principal frequency components corresponding to those of the antiresonance modes,
variations at the system output are very small.
 Solar systems are in general expensive in terms of the energy produced and so any improvements in
performance that could be gained through the use of advanced control techniques would help to
present them as a viable alternative to conventional energy sources.

A solar collector is essentially a very large heat exchanger and these types of systems are quite
common in process industry, then most of the experience gained with the control of solar collector
fields can be used for other, more common, industrial processes.

These aspects render the control problem at hand a difficult one and call for the use of carefully designed
control algorithms, presenting enough robustness to cope with the high levels of uncertainty present in the
plant. The activities performed by the control groups related to this field cover modelling, identification and
simulation, classical proportional-integral-derivative control (PID), feedforward control (FF), model based
predictive control (MPC), adaptive control (AC), gain-scheduled control (GS), cascade control (CC), internal
model control (IMC), time delay compensation (TDC), optimal control (LQG), nonlinear control (NC),
robust control (RC), fuzzy logic control (FLC) and neural network controllers (NNC) [12].

As earlier was mentioned, Apros simulation tool provides all needed blocks to construct full controlled
simulation model. In this model there are typical PI-controllers, valves, pumps and fans including also
actuators which are familiar from “real” Distributed Control System (DCS). There are several control
schemes like boiler fuel feed, primary and secondary air, steam temperature, furnace pressure, air preheaters,
drum level, flue gas oxygen and feed water controllers which are used in real power plants. There are several
methods in the markets how to control CSP steam production. In this simulation study for steam generation
control of the CSP-plant PI-controllers are conducted.

4.2.1 The boiler controls

The boiler load control is so called “Boiler follow” control where the load set point is defined as megawatts.
The measurement is acquired from turbine generator. This PI-controller is controlling the position of
governor valve. When the boiler load is decreased MW-set point is decreased which causes the governor
valve closing. For the drum pressure this means drum pressure increasing when the drum pressure controller
will decrease fuel feeding into the boiler. The boiler follow mode is illustrated in the Figure 10 [22].

Based on the fuel feeding air amount is calculated via stoichiometric coefficient. Air amount is then divided
to the primary and secondary air controllers and flue gas O2-controller is adjusting secondary air amount
according to burning conditions (oxygen level). Like in real boiler furnace pressure is controlled to acquire
under pressure in the furnace. Feed water amount is based on the final steam generation which is corrected
with the drum level controller. There are two desuperheaters which are controlling the final steam
temperature. Additionally there are several “lower level” controllers which will not be introduced in this
paper.

Figure 10. The principle of the boiler follow mode control.

 4.2.2 The solar field control

Water circulation pump to the solar field starts when the irradiance is high enough in the morning. The feed
water pump and valve control are also based on the irradiance which gives basic feed water amount to the
field. The modelling approach is based on modelling on representative collector row.

All the controls are carried out by proportional-integral (PI) controllers, as they are widely used standard
controllers. The following principles are followed in the plant control scheme:

Evaporator inlet mass flow regulated by a control valve in order to ensure sufficient cooling of
receiver tubes by means of the evaporator outlet steam quality.
Feed water and recirculation pumps shut down for the night.
Superheater recirculation applied before start-up and after shut down by a pump and a control
valve.
One spraying water flow line in the superheating section to ensure stable superheater outlet
steam temperature and to avoid overheating in the receiver tubes.
Start-up and shut down are carried out with PI controllers automatically, and there are no
separate sequences for start-up and shut down. [23]

5. Simulation results
In this simulation example there was 24 hours total simulation time. Simulation started at 00.00 21st of June
in Quarzazate, Marocco. In the diagrams is illustrated when sun starts to heat up the solar field steam
production will start after the steam parameters are acceptable to the boiler to replace the first turbine tap,
actually feed water HP-preheater two. The solar field was designed to just replace one HP-preheater of the
turbine island and there were four collector units in use. Using additional units would produce too much
power which would conduct to the condensate problem and instability to the boiler feed water heating
system. In the Figure 11, fuel power and electricity production is presented. Approximately at seven in the
morning solar field will start producing steam which can be seen in fuel decreasing in the Figure 11.
Electricity production remains steady and fuel will be saved and this is why this hybrid system is called “fuel
save mode” as earlier described in theoretical part.
 Fuel power and electricity production
Electric power (MWe) Fuel power (MW)

400

350

300

250

200

150

100
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 11. Fuel power and electricity production in the hybrid system.

In the next Figure 12, boiler feed water and main steam flows are presented. This figure presents how steam
generation will decrease when the CSP field starts providing steam to the turbine unit.

Feed water and main steam flows

Feedwater flow (kg/s) Main steam mass flow (kg/s)

109

107

105

103

101

99

97

95
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 12. Feed water and main steam flows.

In the Figure 13, flue gas oxygen content is presented. As can be seen there is no remarkable influences
when CSP field is starting to provide steam. The control system will take care of fuel fluently decreasing. O2-
controller is controlling the amount of secondary air.
 Flue gas oxygen content (mole-%)
5

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours
Figure 13. Flue gas oxygen content.

In the Figure 14, fuel flow into the boiler is presented. On peak load of solar field at noon, 2.2 kg/s fuel will
be saved. Fuel moisture is 30%.

Fuel flow (kg/s)

30

30

29

29

28

28

27

27

26

26

25
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 14. Fuel flow.

As in the Figure 15 can be seen there are no remarkable changes in the boiler feed water and pressure.
 Feed water pressure and temperature
Feedwater pressure (bar) Feedwater temperature (°C)

170
168
166
164
162
160
158
156
154
152
150
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 15. The boiler feed water pressure and temperature.

Feed water of the CSP field is taken before the boiler feed water pump. CSP field is designed to produce
steam with the similar parameters as turbine first tap.

CSP feed water and final steam

temperatures
CSP Feedwater temperature (°C) CSP main steam temperature (°C)
400

350

300

250

200

150

100
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 16. CSP feed water and final steam temperatures.

In the Figure 17, CSP feed water flow and pressure are illustrated. Feed water is taken before the boiler feed
water pump. Feed water amount to the solar field at maximum point is 7.5 kg/s.
 CSP feed water flow and pressure
CSP Feedwater flow (kg/s) CSP Feedwater pressure (bar)

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 17. CSP feed water flow and pressure.

In the Figure 18, the first turbine tap flow to the preheater is presented. At full load, steam from the CSP
field substitutes the whole steam flow from the turbine tap.

HP-heater mass flow (kg/s)

HP FWH2 mass flow

20
18
16
14
12
10
8
6
4
2
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time in hours

Figure 18. HP-heater steam mass flow from turbine.

 6. Conclusion
In this simulation study, an integrated hybrid power plant was constructed. The bubbling bed natural
circulation boiler was modelled with all needed heat exchangers in gas and water/steam parts. The turbine
island included HP-, IP- and LP- turbine sections with required taps, condensate tank and pumps with LP-
preheating system and feed water preheating system. Linear Fresnel solar field was constructed of the
evaporator and the superheating part where recirculation water tank was used to separate water/steam
suspension.

The simulation total time was 24 hours. In the morning, when the CSP steam parameters were acceptable,
the automation system started all the pumps and opened the valves automatically and CSP steam started to
substitute tap steam to the HP-preheater. At the same time fuel feeding was decreased but electricity
production was steady which means driving of the hybrid system on “fuel saving mode”. The control system
of the boiler included all the needed controllers for handling CSP field production changes.

There is a remarkable advantage to have a possibility to simulate these kinds of large and complicate
processes. The simulation provides additional information when new concepts of processes, automation or
integration of existing or new processes are developed and evaluated. It is also very cost effective way to
have conception “how process should work in the future as an optimized and effectively way as possible”.
Apros simulation programme provides all needed tools for this kind of dynamic simulation studies.

Acknowledgements
This work was carried out in the Combo-CFB (Combination of Concentrated Solar Power with Circulating
Fluidized Bed Power Plants) research project coordinated by VTT Technical Research Centre of Finland
with funding from the Finnish Funding Agency for Innovation, Tekes.
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