CN115268300A - Fault simulation method for communication link of electronic controller of gas turbine control system - Google Patents

Fault simulation method for communication link of electronic controller of gas turbine control system Download PDF

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CN115268300A
CN115268300A CN202210909114.2A CN202210909114A CN115268300A CN 115268300 A CN115268300 A CN 115268300A CN 202210909114 A CN202210909114 A CN 202210909114A CN 115268300 A CN115268300 A CN 115268300A
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communication link
performance index
fault
index value
gas turbine
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尹德斌
秦佳晖
闫鹏宇
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Shanghai Institute of Process Automation Instrumentation
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Abstract

The invention provides a fault simulation method for a communication link of an electronic controller of a gas turbine control system, and relates to the technical field of fault diagnosis of a gas turbine power plant. The method comprises the following steps: acquiring a sensor process signal from a gas turbine controller system, and performing data preprocessing to form an original data set; inputting an original data set into an IO board card fault simulation module, adding fault form data, and adjusting board card performance calculation parameters to enable the performance index value of the board card to deviate from a preset performance index normal range; inputting the performance index value of the board card into a communication link performance calculation module, and calculating the performance index value of the link; and judging whether the performance index value of the link exceeds a preset normal range or not, and determining whether the communication link fails or not according to the performance index value. The method can be used for design verification of a fault state diagnosis algorithm of the communication link by obtaining the performance index value of the communication link in the fault state, and provides decision support for fault diagnosis of the gas turbine control system loop.

Description

Fault simulation method for communication link of electronic controller of gas turbine control system
Technical Field
The invention relates to the technical field of fault diagnosis of gas turbine power plants, in particular to a fault simulation method for a communication link of an electronic controller of a gas turbine control system.
Background
With the increasing maturity of gas turbines and their combined cycle technologies, as well as the massive development of natural gas resources worldwide and the increasing pressure on global environmental protection, gas turbine power generation is not only used as an emergency backup power source and peak load, but also used as clean energy, distributed energy and base load to deliver power to the power grid. Gas turbines are growing and developing rapidly today in the field of power generation; in the background of carbon peak carbon neutralization, the power generation of a gas turbine using hydrogen as fuel is regarded and greatly developed unprecedentedly.
The gas turbine control system is a complex nonlinear dynamic system formed by integrating a large number of parts according to certain modes, functions and requirements. An electronic controller (DCS system) in a gas turbine control system is the core and key of the whole gas turbine control system. How to effectively diagnose faults of an electronic controller of a fuel control system is a difficult problem in the industry. The conventional fault diagnosis method of the electronic controller based on the BIT technology needs to add a large number of redundant diagnosis circuits in the electronic components, which increases the system cost on one hand and also adds a new electronic fault point on the other hand. Different manufacturers of gas turbine control systems have a plurality of professional system diagnosis functions built in their respective DCS systems, and these functions must be checked in engineer operation stations with corresponding authorities, and the information acquisition process is passive, requiring operators to find various alarm information at different positions, and then combining various paper data of paper edition, even needing to actually check the hardware indication state in the DCS cabinet, to judge the fault point of the system. Further determination of the cause of the failure is more of the individual abilities and experience of the engineer. The method seriously restricts the quick judgment of the system fault of the gas turbine power plant, and as a result, the unplanned shutdown caused by the false alarm of an electronic controller system frequently occurs, thereby causing great economic loss to the power plant.
The DCS system is composed of high-precision and high-density electronic components/chips, the working principle and failure mechanism of various components are completely different, the failure mode is often 'sudden', and the problem of fault detection cannot be effectively solved at all only by means of daily checking means and testing means. In the daily operation process of the gas turbine, taking the most important temperature parameter of the combustion chamber as an example, the stability and consistency of the group of parameters (the 9F unit is 31 measuring points which are arranged in a circumferential mode) are directly related to whether the unit can continuously operate or not; once a measurement distortion due to a communication link failure occurs, an immediate shutdown may be required with very serious consequences.
The research on the data-driven fault diagnosis method of the communication link of the electronic controller has the defects that the lack of practical fault samples is a main bottleneck for restricting the development and application of a diagnosis algorithm, and how to effectively obtain the fault samples with practical value is always a difficult problem in the industry.
Disclosure of Invention
The invention aims to provide a fault simulation method for a communication link of an electronic controller of a gas turbine control system, aiming at overcoming the defects of the prior art, and solving the problems that a fault sample is difficult to obtain and the fault diagnosis method cannot be effectively verified in the fault diagnosis problem of the communication link of the electronic controller in the gas turbine control system.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
the invention provides a method for simulating a communication link fault of an electronic controller of a gas turbine control system, which comprises the following steps:
acquiring a sensor process signal of a gas turbine system from a gas turbine electronic controller system, and performing data preprocessing to form a sensor signal original data set;
inputting a sensor signal original data set into an IO board card fault simulation module, and adjusting performance calculation weight parameters of the IO board card by adding preset fault form data to enable the obtained performance index value of the IO board card to deviate from a preset normal interval range of the IO board card performance index;
inputting the obtained performance index value of the IO board card into a communication link performance calculation module, and calculating the performance index value of the communication link;
and judging whether the performance index value of the communication link obtained by calculation exceeds the range boundary of the preset normal interval of the performance index of the communication link, and determining whether the communication link fails according to the judgment result, thereby realizing the fault state simulation of the communication link.
Alternatively, sensor process signals of the combustion engine system are obtained from a gas turbine electronic controller system in OPC UA industrial protocols.
Optionally, real-time process data of all sensors associated with the target communication link are acquired from the gas turbine electronic controller DCS system through an OPC UA industrial protocol interface, and the data preprocessing includes a redundant sample elimination operation, an abnormal sample elimination operation, and a data normalization operation.
Optionally, the preset fault pattern includes: sudden offset faults, short-time interference faults, time offset faults, periodic interference faults, and random interference faults; in an IO board card fault simulation module, simulating a sensor signal to generate a sudden change offset fault by using a step signal; simulating a short-time interference fault of a sensor signal by using a pulse signal; simulating the occurrence of a time offset fault of a sensor signal by using a linear signal with a preset slope; simulating a periodic interference fault of a sensor signal by using a periodic sine wave signal; and simulating the occurrence of random interference faults of the sensor signal by using a Gaussian white noise signal.
Optionally, the performance index value of the IO board is calculated by:
using the sensor residual error sequence weighted square sum based on the unscented Kalman filter as the performance index value of the sensor,
Figure BDA0003773387140000031
∑＝(diag(σ))2
wherein R isiThe performance index value of a sensor corresponding to the ith channel of the IO board card is obtained, filters corresponding to m sensors associated with the IO board card are established based on an unscented Kalman filter, the input of each filter is m-1 measurement parameter values, the input of the ith filter is the measurement parameters of the rest m-1 sensors except the ith sensor, sigma is the standard deviation of the measurement parameters, y is the standard deviation of the measurement parameters, and the performance index value of the sensor corresponding to the ith channel of the IO board card is obtained by the method that(i)For measurement of the ith filterThe parameters are set to be in a predetermined range,
Figure BDA0003773387140000041
predicting an output for the i-th filter nonlinear model; m is the total number of sensors associated with the IO board card;
then calculating the performance index value of the IO board card by using a weighted summation mode based on the performance index value of the sensor,
Figure BDA0003773387140000042
wherein R isIOIs the performance index value, k, of the IO board cardiIs the weighting of the ith channel of the IO board.
Optionally, the performance indicator value of the communication link is calculated by:
weighting and summing the performance index values of all IO boards associated with the communication link to serve as the performance index value of the communication link,
Figure BDA0003773387140000043
wherein R isLINKAs a performance index value for the communication link,
Figure BDA0003773387140000044
is the performance index value l of the ith IO board card of the communication linkiAnd n is the total number of all IO boards associated with the communication link.
The beneficial effects of the invention include:
the invention provides a method for simulating the fault of a communication link of an electronic controller of a gas turbine control system, which comprises the following steps: acquiring a sensor process signal of a gas turbine system from a gas turbine electronic controller system, and performing data preprocessing to form a sensor signal original data set; inputting a sensor signal original data set into an IO board card fault simulation module, and adjusting performance calculation weight parameters of the IO board card by adding preset fault form data to enable the obtained performance index value of the IO board card to deviate from a preset IO board card performance index normal interval range; inputting the obtained performance index value of the IO board card into a communication link performance calculation module, and calculating the performance index value of the communication link; and judging whether the performance index value of the communication link obtained by calculation exceeds the range boundary of the normal interval of the preset performance index of the communication link, and determining whether the communication link fails according to the judgment result, thereby realizing the fault state simulation of the communication link. The method can be used for design verification of a fault state diagnosis algorithm of the communication link by obtaining the performance index value of the communication link in the fault state, and provides decision support for fault diagnosis of the gas turbine control system loop.
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In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the embodiments or the prior art descriptions will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic flow diagram illustrating a method for simulating a fault in a communication link of an electronic controller of a gas turbine control system according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a gas turbine control system electronic controller communication link fault simulation experiment device provided by the embodiment of the invention;
FIG. 3 is a schematic diagram illustrating an actual operation flow of a simulation method for a fault of a communication link of an electronic controller of a gas turbine control system according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The electronic controller in the gas turbine control system is a complex system formed by highly integrated electronic components, and the BIT-based fault diagnosis method is high in implementation cost, and a newly-added fault diagnosis loop increases the complexity of the system on one hand and additionally increases the fault probability of the system on the other hand. Data-based fault diagnosis methods are a recent research focus. However, the data-based fault diagnosis method requires a large number of high-quality fault samples for algorithm training and verification. The inability to generate enough fault samples at the industrial site (it is well understood that if the fault samples at the industrial site are abundant, this indicates that the process is not mature and is not capable of wide industrial application), results in that data-based fault diagnosis methods often perform well only in a laboratory environment and cannot be truly used at the industrial site.
In order to solve the problems, the invention provides a convenient and feasible communication link fault simulation method.
Fig. 1 is a schematic flow chart illustrating a simulation method for a fault of a communication link of an electronic controller of a gas turbine control system according to an embodiment of the present invention, where as shown in fig. 1, the simulation method for a fault of a communication link of an electronic controller of a gas turbine control system according to the present invention includes:
step 101, obtaining a sensor process signal of a gas turbine system from a gas turbine electronic controller system, and performing data preprocessing to form a sensor signal original data set.
Sensor process signals for a combustion engine system are obtained, for example, from a 9F unit gas turbine control system electronic controller system using natural gas fuel.
Step 102, inputting the original data set of the sensor signal into an IO board card fault simulation module, and adjusting the performance calculation weight parameter of the IO board card by adding preset fault form data, so that the obtained performance index value of the IO board card deviates from the preset normal interval range of the performance index of the IO board card. That is to say, the performance index value of the IO board is obtained by inputting the data superimposed with the fault signal into the IO board performance index value calculation model.
Step 103, inputting the obtained performance index value of the IO board card into a communication link performance calculation module, and calculating the performance index value of the communication link;
and step 104, judging whether the performance index value of the communication link obtained by calculation exceeds the range boundary of the preset normal interval of the performance index of the communication link, and determining whether the communication link fails according to the judgment result, thereby realizing the fault state simulation of the communication link.
Based on the fact that the signal state of the related sensors of the communication link of the electronic controller is abnormal after the communication link is failed, the first reaction of the failure of the communication link is the signal abnormality of the sensors. According to the method, the performance index value of the IO board card is abnormal by means of superimposing the fault signal in the sensor signal data, and further the performance index value of the communication link is abnormal, so that the form of the communication link in a fault state is simulated. By using the method, a large number of fault samples can be conveniently generated, the problem of sample missing in the fault diagnosis of the communication link of the electronic controller is solved, and a foundation is provided for further fault diagnosis of the communication link. The method can be used for design verification of a fault state diagnosis algorithm of the communication link by obtaining the performance index value of the communication link in the fault state, and provides decision support for fault diagnosis of the gas turbine control system loop.
Alternatively, sensor process signals for the gas turbine system are obtained from an OPC Server data source connected to the gas turbine electronic controller system in OPC UA industrial protocols from the gas turbine electronic controller system.
Optionally, real-time process data of all sensors associated with the target communication link are acquired from the gas turbine electronic controller DCS system through an OPC UA industrial protocol interface from the gas turbine electronic controller system, and the data preprocessing includes removing redundant sample operation, removing abnormal sample operation and data normalization operation, and the data is converted into a gaussian distribution shape with 0 mean value and 1 variance.
Optionally, the preset fault pattern includes: sudden offset faults, short-time interference faults, time offset faults, periodic interference faults, and random interference faults; in an IO board card fault simulation module, a step signal is utilized to simulate a sudden change deviation fault of a sensor signal; simulating a short-time interference fault of a sensor signal by using a pulse signal; simulating the occurrence of a time offset fault (temperature drift) of the sensor signal by using a straight line signal with a preset slope; the periodic sine wave signals are used for simulating the occurrence of periodic interference faults (such as high-power electrical equipment interference) of the sensor signals; the Gaussian white noise signal is used for simulating random interference faults (such as poor grounding/poor contact) of the sensor signal.
Optionally, the performance index value of the IO board is calculated by:
using the sensor residual error sequence weighted square sum based on the unscented Kalman filter as the performance index value of the sensor,
Figure BDA0003773387140000081
∑＝(diag(σ))2
wherein R isiThe performance index value of a sensor corresponding to the ith channel of the IO board card is obtained, filters corresponding to m sensors associated with the IO board card are established based on an unscented Kalman filter, the input of each filter is m-1 measurement parameter values, the input of the ith filter is the measurement parameters of the rest m-1 sensors except the ith sensor, sigma is the standard deviation of the measurement parameters, y is the standard deviation of the measurement parameters, and the performance index value of the sensor corresponding to the ith channel of the IO board card is obtained by the method that(i)For the measured parameter of the i-th filter,
Figure BDA0003773387140000082
predicting an output for the i-th filter nonlinear model; m is the total number of sensors associated with the IO card.
Figure BDA0003773387140000083
As can be seen from the above equation, the unscented Kalman filter may be based on measurements of the gas turbineParameter ykAnd nonlinear model prediction output
Figure BDA0003773387140000084
The parameter p is estimated by the residual error, and the output parameter of the model tracks the output of the real gas turbine by updating the parameter of the nonlinear model, so that the estimation of the gas turbine parameter is realized.
Then calculating the performance index value of the IO board card by using a weighted summation mode based on the performance index value of the sensor,
Figure BDA0003773387140000085
wherein R isIOIs the performance index value, k, of the IO board cardiIs the weighting of the ith channel of the IO board.
Optionally, the performance indicator value of the communication link is calculated by:
weighting and summing the performance index values of all IO boards associated with the communication link to serve as the performance index value of the communication link,
Figure BDA0003773387140000091
wherein R isLINKAs a performance index value for the communication link,
Figure BDA0003773387140000092
is the performance index value l of the ith IO board card of the communication linkiAnd n is the total number of all IO boards associated with the communication link.
FIG. 2 shows a schematic diagram of a gas turbine control system electronic controller communication link fault simulation experiment device provided by the embodiment of the invention. FIG. 3 is a schematic diagram illustrating an actual operation flow of a communication link failure simulation method of an electronic controller of a gas turbine control system according to an embodiment of the present invention. A flow chart of a fault simulation of a particular actual gas turbine control system communication link is shown in FIG. 3.
After a communication link based on an electronic controller has a fault, the state of a sensor signal acquired by a system is abnormal, such as a value suddenly jumps (step fault), the value returns to normal (pulse fault) after suddenly jumping, the value continuously increases or decreases (time-varying/temperature-drifting fault), the value has periodic interference (often because a strong electric induction signal is mixed in the board), or the signal stability deteriorates (white noise interference, often caused by poor contact or abnormal grounding). The first reaction that the communication link has a fault is that the sensor signals are abnormal, and the invention makes use of the mode of superposing the fault signals in the sensor signal data to make the performance index value of the IO board card associated with the communication link abnormal, thereby causing the performance index value of the communication link to exceed the range of the normal interval, and realizing the simulation of the fault state of the communication link. The method can conveniently generate a large number of fault samples, solves the problem of sample missing in the fault diagnosis of the communication link of the electronic controller, and provides a basis for further fault diagnosis of the communication link.
The above-mentioned embodiments are only for illustrating the technical idea and features of the present invention, and the purpose of the present invention is to enable those skilled in the art to understand the content of the present invention and implement the present invention, and not to limit the protection scope of the present invention, and all equivalent changes or modifications made according to the spirit of the present invention should be covered in the protection scope of the present invention.

Claims (6)

1. A method for simulating a fault in a communication link of an electronic controller of a gas turbine control system, the method comprising:
acquiring a sensor process signal of a gas turbine system from a gas turbine electronic controller system, and performing data preprocessing to form a sensor signal original data set;
inputting the original sensor signal data set into an IO board card fault simulation module, and adjusting performance calculation weight parameters of the IO board card by adding preset fault form data to enable the obtained performance index value of the IO board card to deviate from a preset normal interval range of the performance index of the IO board card;
inputting the obtained performance index value of the IO board card into a communication link performance calculation module, and calculating the performance index value of the communication link;
and judging whether the performance index value of the communication link obtained by calculation exceeds the range boundary of the preset normal interval of the performance index of the communication link, and determining whether the communication link fails according to the judgment result, thereby realizing the fault state simulation of the communication link.
2. The gas turbine control system electronic controller communication link fault simulation method of claim 1, wherein sensor process signals of a combustion engine system are obtained from said gas turbine control system in OPC UA industrial protocols.
3. The gas turbine control system electronic controller communication link fault simulation method of claim 2, wherein real-time process data of all sensors associated with a target communication link is acquired from a gas turbine electronic controller DCS system with OPC UA industrial protocol interface from the gas turbine electronic controller system, and the data preprocessing includes redundant sample elimination, abnormal sample removal, and data normalization.
4. The gas turbine control system electronic controller communication link fault simulation method of claim 1, wherein the preset fault profile comprises: sudden offset faults, short-time interference faults, time offset faults, periodic interference faults, and random interference faults; in an IO board card fault simulation module, simulating a sensor signal to generate a sudden change offset fault by using a step signal; simulating a short-time interference fault of a sensor signal by using a pulse signal; simulating the occurrence of a time offset fault of a sensor signal by using a straight line signal with a preset slope; simulating a periodic interference fault of a sensor signal by using a periodic sine wave signal; and simulating the occurrence of random interference faults of the sensor signal by using a Gaussian white noise signal.
5. The method for simulating the fault of the communication link of the electronic controller of the gas turbine control system according to claim 1, wherein the performance index value of the IO board card is calculated by:
using the sensor residual error sequence weighted square sum based on the unscented Kalman filter as the performance index value of the sensor,
Figure FDA0003773387130000021
∑＝(diag(σ))2
wherein R isiThe performance index value of a sensor corresponding to the ith channel of the IO board card is obtained, filters corresponding to m sensors associated with the IO board card are established based on an unscented Kalman filter, the input of each filter is m-1 measurement parameter values, the input of the ith filter is the measurement parameters of the rest m-1 sensors except the ith sensor, sigma is the standard deviation of the measurement parameters, y is the standard deviation of the measurement parameters(i)For the measured parameter of the i-th filter,
Figure FDA0003773387130000022
predicting an output for the i-th filter nonlinear model; m is the total number of sensors associated with the IO board card;
then based on the performance index value of the sensor, the performance index value of the IO board card is calculated by using a weighted summation mode,
Figure FDA0003773387130000023
wherein R isIOIs the performance index value, k, of the IO board cardiIs the weighting of the ith channel of the IO board.
6. The gas turbine control system electronic controller communication link fault simulation method of claim 5, wherein the performance index value of the communication link is calculated by:
weighting and summing the performance index values of all IO boards associated with the communication link to serve as the performance index value of the communication link,
Figure FDA0003773387130000031
wherein R isLINKAs a performance index value for the communication link,
Figure FDA0003773387130000032
is the performance index value l of the ith IO board card of the communication linkiAnd n is the total number of all IO boards associated with the communication link.
CN202210909114.2A 2022-07-29 2022-07-29 Fault simulation method for communication link of electronic controller of gas turbine control system Pending CN115268300A (en)

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