CN115617022A - Control loop fault diagnosis and self-healing system and method - Google Patents
Control loop fault diagnosis and self-healing system and method Download PDFInfo
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- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
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Abstract
The invention provides a control loop fault diagnosis and self-healing system, which comprises a controller and is characterized in that set value data and measured value data are received; a register, wherein the controller output at a previous time is stored; a diagnostic self-healing decision maker configured to receive the controller output and the register output for fault diagnosis and self-healing; the regulating valve is characterized by being controlled by the diagnosis self-healing decision maker; and a control object, characterized by being controlled by the regulating valve.
Description
Technical Field
The invention relates to the technical field of petrochemical industry, in particular to a control loop fault diagnosis and self-healing system and a control loop fault diagnosis and self-healing method.
Background
At present, in petrochemical production, PID single-loop control is a basic control unit, and the automatic utilization rate of the PID single-loop control directly determines the automation level of a production device. The control loop generally adopts a PID control algorithm, the operation mode is Automatic (AUTO) under the normal condition, the control is stable, and the requirement can be met. However, the production process is disturbed by various predictable and unpredictable factors, and in severe cases, the device triggers interlocking protection to stop, so that a great economic loss is caused.
Take a delayed coking process furnace as an example. The delayed coking process is mainly used for processing various heavy crude oils and residual oils, and the oil products are heavier and even contain coke blocks. When the coke block in the feeding is large, the feeding pipeline can be blocked, so that the feeding is reduced sharply, the temperature at the outlet of the furnace rises violently, the pressure of the fuel gas drops, when the valve position of the fuel gas is reduced to a threshold value, the interlocking protection is triggered to cause the flameout of the heating furnace, the process is completed within one minute, and the operator has no reaction time. Delayed coking as a petroleum processing tap presents problems and all subsequent sections are affected. Besides the influence of external factors, the communication fault of the DCS system can also cause abnormal fluctuation of the valve position of the control loop. The measured value of the field measurement transmitter can not be transmitted to the controller in real time, the value read by the controller at the moment can be constant (bad value) or zero, and the valve position output calculated by taking the value as a reference can have large deviation, so that the interlocking protection is triggered.
The fault diagnosis and self-healing of the current control loop depend on manual observation, and a manual adjustment method is adopted. And after finding problems, an operator switches the controller into a manual mode, and switches back to an automatic mode after external influence factors disappear or internal communication is normal. The manual observation and adjustment method completely depends on the experience and the reaction speed of operators, but some quick process objects often have quick response, and the manual adjustment is not timely, so that serious consequences are caused. Therefore, there is a need in the art for a system and method for diagnosing and self-healing a control loop fault, which can automatically diagnose and self-heal the control loop when the control loop is abnormal, and adjust the control loop to the operation range of the process design.
Disclosure of Invention
The invention aims to provide a control loop fault diagnosis and self-healing system, which comprises a controller and is characterized in that set value data and measured value data are received; a register, wherein a last time controller output is stored; a diagnostic self-healing decision maker configured to receive the controller output and the register output for fault diagnosis and self-healing. The regulating valve is characterized by being controlled by the self-healing decision maker; the control object is characterized by being controlled by the regulating valve.
Further, the control loop fault diagnosis and self-healing system, wherein the fault diagnosis module further comprises a DCS system valve value MV; self-healing upper limit MV for manually setting valve position SH With the lower limit MV of the self-healing of the manual setting valve position SL The range is less than the upper limit MV of the valve position of the DCS system H And DCS valve position lower limit MV L (ii) a The variation Δ SV of the set value; the variation Δ PV of the measured values; a flag amount C; and a variation threshold M.
Further, the control loop fault diagnosis and self-healing system, wherein the fault self-healing module further comprises a valve position of the DCS systemThe value MV; a flag amount C; controller calculated value CV t (ii) a AUTO mode AUTO; and manual mode MAN.
Further, the control loop fault diagnosis and self-healing system calculates the valve position output value and compares the valve position output value with the set upper limit value and the set lower limit value.
Further, the control loop fault diagnosis and self-healing system further comprises a calculation module, wherein the calculation model is as follows:
the invention discloses a control loop fault diagnosis and self-healing method, which comprises the steps of receiving set value data and measured value data; judging and outputting the numerical range of the current moment; and receiving the value of the current time, and automatically adjusting the output and control mode of the controller.
Further, the control loop fault diagnosis and self-healing method calculates the valve position output value and compares the valve position output value with the set upper limit value and the set lower limit value.
Further, the control loop fault diagnosis self-healing method comprises the following steps:
drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the description in the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a schematic diagram of upper and lower self-healing limits of a valve position provided by the present invention;
FIG. 2 is a block diagram of a prior art single-loop control;
FIG. 3 is a block diagram of a single-loop control with the addition of a register and a diagnostic self-healing decision maker according to the present invention;
fig. 4 is a schematic diagram of a post-SV change adjustment effect without a diagnostic self-healing decision maker of case 1 according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of the effect of SV change post-conditioning in case 1 with the addition of a diagnostic self-healing decision maker;
fig. 6 is a schematic diagram of the PV regulation effect after the PV fluctuation of the non-diagnostic self-healing decision maker according to the embodiment of the present invention in case 2;
FIG. 7 is a schematic diagram of the adjustment effect of the self-healing diagnostic decision maker in case 2 after PV fluctuation;
FIG. 8 is a schematic diagram of the adjustment effect of the self-healing diagnostic decision maker in case 3 after PV has fluctuated;
FIG. 9 is a schematic diagram of the adjustment effect after PV added to the diagnostic self-healing decision maker fluctuates in case 4;
FIG. 10 is a schematic diagram of the adjustment effect of the case 5 without the diagnostic self-healing decision maker; and
fig. 11 is a schematic diagram of the adjustment effect of the case 5 with the addition of the diagnostic self-healing decision maker.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplification of description, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
The present invention will be further explained with reference to specific embodiments.
Fig. 1 is a schematic diagram of upper and lower self-healing limits of a valve position provided by the present invention. The purpose of the present invention as shown in fig. 1 is to provide a method for fault diagnosis and self-healing of a control loop in an automatic mode. The method can be used for diagnosing the fault of the control circuit on the basis that the control circuit is in the automatic mode, and valve position output is selected as a judgment signal. The self-healing upper limit and the self-healing lower limit of the valve position are manually set in advance according to the process requirements, and the range is slightly smaller than the upper limit and the lower limit of DCS.
And when the valve position is lower than the self-healing lower limit and continuously reduced or higher than the self-healing upper limit and continuously increased, diagnosing that the control loop is in an abnormal state at the moment, starting a self-healing program, and outputting a value when the valve position is in the moment before the abnormality. If the valve position is directly lower than the DCS set lower limit or higher than the DCS set upper limit due to external influence or error input, the control loop is diagnosed to be in an abnormal state at the moment, a self-healing program is started, the valve position is output at the moment before the abnormality, and the controller mode is switched to a manual Mode (MAN). The whole stable operation of the device is ensured, and the accidental interlocking is prevented. In order to achieve the purpose, in the technical scheme of the invention, a diagnosis self-healing decision maker is added in the DCS, and a fault diagnosis and self-healing panel is added in a monitoring picture. And an operator sets the self-healing upper and lower limits and starts the functions on the monitoring picture to realize the diagnosis and self-healing functions.
FIG. 2 is a block diagram of a prior art single loop control. As shown, G(s) is the transfer function of the control object, G C (s) is the transfer function of the controller, G F (s) is the transfer function of the regulating valve, G M (s) is the transfer function of the measuring transmitter, and SV(s), DV(s), and CV(s) are Laplace transforms of a given value, interference, and output, respectively. The following equation can be obtained:
transfer function of control channel:
transfer function of interference channel:
the output is then:
but at this time, the signal flow passes through G without the functions of diagnosis and self-healing C (s) direct transfer to G F (s), large external disturbances and system faults and even erroneous operator settings can cause large fluctuations in the valve position and trigger interlocks.
Fig. 3 is a block diagram of a single-loop control system with a self-healing diagnostic decision maker according to the present invention. As shown, the fault diagnosis and self-healing system includes a controller, and is characterized by receiving set-point data and measured value data. A register, wherein the last time controller output is stored. A diagnostic self-healing decision maker configured to receive the controller output and the register output for fault diagnosis and self-healing. A regulator valve, characterized by being controlled by the controller. The control object is characterized by being controlled by the regulating valve. A fault diagnosis module configured to determine that the controller outputs a current time value range. And the fault self-healing module is characterized by receiving the current time numerical value of the register and automatically adjusting the output and control mode of the controller. The fault diagnosis module also comprises a DCS system valve value MV; self-healing upper limit MV for manually setting valve position SH With the self-healing lower limit MV of the manually set valve position SL The range is less than the upper limit MV of the valve position of the DCS system H And the lower limit MV of the valve position of the DCS system L (ii) a The variation Δ SV of the set value; the variation Δ PV of the measured values; a flag amount C; and a variation threshold M. The fault self-healing module also comprises a DCS system valve value MV; a flag amount C; controller calculated value CV t (ii) a AUTO mode AUTO; and manual mode MAN.
Self-healing upper limit MV for manually setting valve position SH With the lower limit MV of the self-healing of the manual setting valve position SL The range is less than the upper limit MV of the valve position of the DCS system H And the lower limit MV of the valve position of the DCS system L And calculating the valve position output value and comparing the valve position output value with the set upper limit value and the set lower limit value.
The calculation method comprises the following steps:
the flag C is the output of the fault diagnosis module.
MV t+1 And MODE t+1 The fault self-healing module is used for calculating the output and the mode of the controller.
Wherein the MV t Is the valve position value, CV, at time t t+1 Calculating the output value, MV, for the controller at time t +1 t-1 Is the valve position value at time t-1, MV t+1 Valve position value at time t +1, MV SH And MV SL The self-healing upper limit and the self-healing lower limit of the valve position, MV, are respectively set manually H And MV L The upper limit and the lower limit of the valve position of the DCS system are respectively, Δ SV is the variation of a set value, Δ PV is the variation of a measured value, M is a variation threshold (namely when the variation amplitude exceeds the value, a fault diagnosis and self-healing module performs corresponding action), and MODE t+1 The mode of the loop at time t +1 (MAN is manual mode, AUTO is automatic mode).
According to a calculation formula, if the valve position at the moment t is within the self-healing upper and lower limit ranges, the valve position output at the moment t +1 is a calculated output value of the controller; if the valve position value at the time t is within the self-healing upper limit and the self-healing lower limit and the DCS valve position upper limit and the self-healing lower limit, the valve position output value at the time t +1 is forcibly arranged in the valve position value at the time t-1 in the register by the fault self-healing module; and if the valve position value at the time t is lower than the lower limit of the DCS valve position or higher than the upper limit of the DCS valve position, the valve position output value at the time t +1 is forcibly set to the valve position value at the time t-1, and the loop mode is forcibly converted into Manual (MAN).
Compared with the existing manual adjustment, the invention has the following beneficial effects.
(1) The interference of some unpredictable emergencies to the whole device is obviously reduced, the large device is prevented from being stopped in an avoidable interlocking manner, and the economic benefit is improved.
(2) The labor intensity of operators is effectively reduced, the problem that manual mode switching is necessary due to interference in a small time period is avoided, and the automatic control rate of the device is improved.
In order to verify the effectiveness of the scheme, simulation verification of the scheme is carried out in a DCS system in combination with an industrial actual production case. The method mainly aims at the following five possible conditions in practical production:
in case 1, an operator mistakenly operates SV, and SV change exceeds a set threshold value M;
in case 2, the PV caused by external interference fluctuates in a large range, and the variation amplitude of the PV exceeds a threshold value M;
in the case 3, the PV is fluctuated in a large range caused by external interference, the variation amplitude of the PV does not exceed the threshold value M, and the variation amplitude of the MV exceeds the upper and lower self-healing limits but does not exceed the upper and lower self limits of the DCS;
in case 4, the PV is fluctuated in a large range caused by external interference, the change amplitude of the PV does not exceed a threshold value M, and the change amplitude of the MV exceeds the upper limit and the lower limit of the DCS;
in case 5, the PV is constant (including zero) due to DCS communication or instrumentation.
The diagnosis and self-healing panel is mainly provided with the following parameters to be set: switching switch, self-healing upper limit and self-healing lower limit. Selecting a retrieval route from a certain atmospheric and vacuum distillation unit to carry out simulation experiment, and setting self-healing upper and lower limits MV SH Is 60,MV SL Is 40; DCS self valve position limiting MV H Is 90,MV L Is 30. The threshold M is set to 40.
Fig. 4 is a schematic diagram of the SV post-change adjustment effect without the diagnostic self-healing decision maker in case 1 according to the embodiment of the present invention. As shown, assume the case: if the operator sets SV by mistake, PV and SV have larger deviation: when the fault diagnosis and fault self-healing module is not put into operation: the deviation of PV from SV due to the mutation of SV is strongly changed by the PID regulation action of the valve position value (MV). This is caused by the misoperation of an operator, but the set value is not allowed to be changed in the actual production, so that the interlocking can be triggered.
Fig. 5 case 1 is a schematic diagram of the post-SV change conditioning effect incorporating the diagnostic self-healing decision maker. After the fault diagnosis and self-healing module is put into use, when SV is in misoperation, the module detects that the variation of a set value exceeds a set threshold value M, the flag quantity C =6, the valve bit value is set to the value at the last moment, and the controller is directly switched to a Manual (MAN) mode (the operation is completed in one machine period, and the actual control valve does not change).
Fig. 6 is a schematic diagram of the PV regulation effect after the PV fluctuation without the diagnostic self-healing decision maker in case 2 according to the embodiment of the present invention. As shown in fig. 6, when PV fluctuates widely due to external influences, the valve position value (MV) fluctuates widely due to the deviation of PV from SV by PID regulation. Adversely affecting the industrial production.
Fig. 7 is a schematic diagram illustrating the adjustment effect after PV fluctuation in case 2, which is added to the diagnostic self-healing decision maker. When the fault diagnosis and fault self-healing module is applied (the PV variation exceeds the threshold M), as shown in fig. 7, it is detected that the PV variation exceeds the set threshold M, the flag C =6, the valve bit value is set to the last time value and the controller directly switches to the Manual (MAN) mode (this is done in one machine cycle, and the actual control valve does not change).
Fig. 8 is a schematic diagram of the adjustment effect after the PV added to the diagnostic self-healing decision maker fluctuates in case 3. When the fault diagnosis and fault self-healing module is used (the PV variation does not exceed the threshold M, and the valve position variation does not exceed the DCS upper and lower limits), as shown in fig. 8, the PV sudden change does not exceed the set threshold M, but the lower limit of the valve position variation at this time exceeds the self-healing lower limit 40, the flag quantity C =2, and the fault self-healing module acts to place the valve position value (MV) in the last time value to wait for the elimination of the external influence.
Fig. 9 is a schematic diagram of the adjustment effect after PV fluctuation in case 4 added to the diagnostic self-healing decision maker. When the fault diagnosis and fault self-healing module is put into use (the PV variation does not exceed the threshold M, and the valve position variation exceeds the upper limit and the lower limit of the DCS), as shown in fig. 9, the sudden change of the PV does not exceed the set threshold M, but the lower limit of the valve position variation at this time exceeds the lower limit 30 of the DCS, the flag C =1, the fault self-healing module acts to set the valve position value (MV) to the last-time numerical value, and the controller directly switches to the Manual (MAN) mode.
Fig. 10 is a schematic diagram of the adjustment effect of the case 5 without the diagnostic self-healing decision maker. When the fault diagnosis and fault self-healing module is not applied, as shown in fig. 10, when the PV value is kept constant or 0 due to an unexpected situation such as a communication fault, the valve position is always in an open or closed state due to the continuous deviation of PV and SV. The valve position will continuously decrease or increase to the upper and lower limits of the DCS itself. In actual production, however, no relevant limitation is generally made on each valve position, and if a problem occurs, a serious accident is caused.
Fig. 11 is a schematic diagram of the adjustment effect of the addition of the diagnostic self-healing decision maker in case 5. When the fault diagnosis and fault self-healing module is used, as shown in fig. 11, the valve position output value is decreased, when the valve position output value is decreased to the self-healing lower limit, the fault diagnosis module judges that the loop is in an abnormal state at the moment, C =2, the valve position output is set at the previous moment and monitored at the moment in subsequent adjustment, and finally the valve position is controlled at 40%.
According to the simulation experiment, the problems of misoperation of an operator, large external interference and large-range fluctuation of a valve position of a control loop caused by system faults are solved by using the fault diagnosis and fault self-healing module, and the follow-up self-healing function of the system is increased.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (9)
1. A control loop fault diagnosis and self-healing system comprises
A controller that receives set value data and measured value data;
a register, wherein a last-time controller output is stored;
a diagnostic self-healing decision maker configured to receive the controller output and the register output for fault diagnosis and self-healing; the control valve is arranged on the base plate,
characterized in that the self-healing decision maker is controlled by the diagnosis self-healing decision maker; and
the control object is characterized by being controlled by the regulating valve.
2. The system according to claim 1, wherein the diagnostic self-healing decision maker further comprises: a fault diagnosis module configured to determine a current time value range output by the controller; and the fault self-healing module is characterized by receiving the current time numerical value of the register and automatically adjusting the output and control mode of the controller.
3. The system of claim 2, wherein the fault diagnosis module further comprises, a DCS system threshold value MV; self-healing upper limit MV for manually setting valve position SH With the self-healing lower limit MV of the manually set valve position SL The range is less than the upper limit MV of the valve position of the DCS system H And DCS valve position lower limit MV L (ii) a The variation Δ SV of the set value; the variation Δ PV of the measured values; a flag amount C; and a variation threshold M.
4. The system according to claim 2, wherein the fault self-healing module further comprises, a DCS system value MV; a flag amount C; controller calculated value CV t (ii) a AUTO mode AUTO; and a manual mode MAN.
5. The system of claim 3, wherein the valve position output value is calculated and compared to the set upper and lower limit values.
6. The system of claim 5, further comprising a calculation module, wherein the calculation model is:
7. a method for diagnosing and self-healing control loop fault comprises
Receiving set value data and measured value data;
judging and outputting the numerical range of the current moment; and
and receiving the numerical value at the current moment, and automatically adjusting the output and control mode of the controller.
8. The method of claim 7, wherein the valve position output value is calculated and compared with the set upper and lower limit values.
9. The method of claim 8, wherein the calculation method is:
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