CN115617022B - 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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- 238000003745 diagnosis Methods 0.000 title claims abstract description 46
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- 238000004364 calculation method Methods 0.000 claims description 9
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- 230000002159 abnormal effect Effects 0.000 description 4
- 230000033228 biological regulation Effects 0.000 description 4
- 230000001960 triggered effect Effects 0.000 description 4
- 230000005856 abnormality Effects 0.000 description 3
- 238000004939 coking Methods 0.000 description 3
- 230000003111 delayed effect Effects 0.000 description 3
- 238000004088 simulation Methods 0.000 description 3
- 239000000571 coke Substances 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000002737 fuel gas Substances 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 230000035772 mutation Effects 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 241001529739 Prunella <angiosperm> Species 0.000 description 1
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- 238000006243 chemical reaction Methods 0.000 description 1
- 230000000875 corresponding effect Effects 0.000 description 1
- 239000010779 crude oil Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
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- 238000009776 industrial production Methods 0.000 description 1
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- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
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- 235000008113 selfheal Nutrition 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- 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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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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; the register is characterized in that the output of the controller at the last moment 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 method.
Background
Currently, 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, and the normal operation mode is Automatic (AUTO), so that the control is stable and the requirements can be met. However, the production process is disturbed by various predictable and unpredictable factors, and the device is triggered to be interlocked for protection to stop when serious, so that a large amount of economic loss is caused.
Take a delayed coking process furnace as an example. The delayed coking process mainly processes various heavy crude oils and residual oils, and the oil products are heavy and even contain coke blocks. When the coke in the feed is large, the feed pipeline is blocked, so that the feed is rapidly reduced, the temperature of the outlet of the furnace is greatly increased, the fuel gas pressure is reduced, when the valve position of the fuel gas is reduced to a threshold value, the interlocking protection is triggered, the heating furnace is flameout, the process is completed within one minute, and no reaction time is needed for operators. And delayed coking as a petroleum processing tap presents problems, all subsequent stations can be affected. Besides the influence of external factors, abnormal fluctuation of the valve position of the control loop can be caused by communication faults of the DCS system. The measured value of the field measurement transmitter may not be transmitted to the controller in real time, and the value read by the controller may be constant (bad value) or zero, so that the valve position output calculated by taking the value as a reference may deviate greatly, and thus 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. After the operator finds out the problem, the controller is switched to the manual mode, and the controller is switched back to the automatic mode after the external influence factors disappear or the internal communication is normal. This method of manual observation adjustment is entirely dependent on the operator experience and reaction rate, but some fast process objects often respond very quickly, and the lack of manual adjustment has serious consequences. Therefore, there is a need in the art for a control loop fault diagnosis and self-healing system and method that automatically diagnoses and self-heals when an abnormality occurs in the control loop, and adjusts the control loop to the operating 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 by receiving set value data and measured value data; the register is characterized by storing the output of the controller at the last moment; a diagnostic self-healing decision maker, configured to receive the controller output and the register output, to perform 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 fault diagnosis and self-healing system of the control loop, wherein the fault diagnosis module further comprises a valve position MV of a DCS system; manually setting valve position self-healing upper limit MV SH And manually setting the valve position self-healing lower limit MV SL The range is smaller than the valve position upper limit MV of the DCS system H And DCS system valve position lower limit MV L The method comprises the steps of carrying out a first treatment on the surface of the The variation DeltaSV of the set value; the amount of change Δpv of the measured value; 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 DCS valve position MV; a flag amount C; controller calculation CV t The method comprises the steps of carrying out a first treatment on the surface of the Automatic mode AUTO; and a manual mode MAN.
Furthermore, the control loop fault diagnosis and self-healing system calculates valve position output values and compares the valve position output values with set upper and lower limit values.
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 current time numerical range; and receiving the current time value and automatically adjusting the output and control mode of the controller.
Furthermore, the control loop fault diagnosis and self-healing method is characterized by calculating valve position output values and comparing the valve position output values with set upper and lower limit values.
Further, the control loop fault diagnosis self-healing method comprises the following steps:
drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings which are required in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are some embodiments of the invention and that other drawings may be obtained from these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of the upper and lower limits of the valve position self-healing provided by the invention;
FIG. 2 is a prior art single loop control block diagram;
FIG. 3 is a block diagram of a single loop control after adding registers and diagnosing a self-healing decision maker according to the present invention;
FIG. 4 is a schematic diagram showing the effect of SV adjustment after change for the diagnostic-free self-healing decision maker of case 1 according to an embodiment of the present invention;
FIG. 5 is a schematic diagram showing the effect of SV change after addition to the diagnostic self-healing decision maker in case 1;
FIG. 6 is a schematic diagram showing the effect of adjusting the PV of the diagnostic-free self-healing decision maker of case 2 after fluctuation;
FIG. 7 is a schematic diagram of the effect of adjusting the PV added to the diagnostic self-healing decision maker in case 2 after fluctuation;
FIG. 8 is a schematic diagram of the effect of adjustment after fluctuation of the PV added to the diagnostic self-healing decision maker in case 3;
FIG. 9 is a schematic diagram of the effect of adjusting the PV of case 4 after fluctuation of the PV of the added diagnostic self-healing decision maker;
FIG. 10 is a schematic diagram of the effect of the adjustment of the diagnostic free-cure decision maker of case 5; and
FIG. 11 is a schematic illustration of the effect of adding a diagnostic self-healing decision maker in case 5.
Detailed Description
The following description of the embodiments of the present invention will be made apparent and fully in view of the accompanying drawings, in which some, but not all embodiments of the invention are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured 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 explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
The invention is further illustrated with reference to specific embodiments.
FIG. 1 is a schematic diagram of the self-healing upper and lower limits of the valve position provided by the invention. The objective of the present invention as shown in fig. 1 is to provide a fault diagnosis and self-healing method for a control loop in an automatic mode. The method can diagnose the fault of the control loop on the basis that the control loop is in an automatic mode, and valve position output is selected as a judging signal. The self-healing upper limit and the self-healing lower limit of the valve position are preset manually according to the process requirements, and the range is slightly smaller than the upper limit and the lower limit set by the DCS.
When the valve position is lower than the lower self-healing limit and continuously decreases or higher than the upper self-healing limit and continuously increases, diagnosing that the control loop is in an abnormal state at the moment, starting a self-healing program, and outputting a value at the moment before the abnormality of the valve position. If the valve position is directly lower than the DCS set lower limit or higher than the upper limit due to external influence or incorrect input, diagnosing that the control loop is in an abnormal state at the moment, starting a self-healing program, outputting a value at the moment before the abnormality of the valve position, and switching the controller mode to a manual state (MAN). The whole stable operation of the device is ensured, and accidental interlocking is prevented. In order to achieve the above purpose, in the technical scheme of the invention, a diagnosis self-healing decision device is added in a DCS system, and a fault diagnosis and self-healing panel is added on a monitoring picture. Setting the upper limit and the lower limit of the self-healing and starting the functions on a monitoring picture by an operator, so as to realize the functions of diagnosis and self-healing.
FIG. 2 is a prior art single loop control block diagram. As shown in the figure, 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 transducer, and SV(s), DV(s) and CV(s) are respectively given value, interference and output Laplace transformation. The following formula can be derived:
transfer function of control channel:
transfer function of the interference channel:
the output is:
but without diagnostic and self-healing functions, the signal flow goes through G C (s) then directly transported to G F (s) external disturbances and system malfunctions and even erroneous input of operator settings can cause large fluctuations in valve position and thus trigger interlocks.
FIG. 3 is a block diagram of a single loop control with the addition of a diagnostic self-healing decision maker according to the present invention. As shown, the fault diagnosis and self-healing system includes a controller, wherein set point data and measured value data are received. A register, characterized in thatAnd outputting by a time controller. A diagnostic self-healing decision maker, configured to receive the controller output and the register output, to perform fault diagnosis and self-healing. The regulating valve is characterized by being controlled by the controller. The control object is characterized by being controlled by the regulating valve. The fault diagnosis module is configured to judge the numerical range of the current moment output by the controller. The fault self-healing module is characterized by receiving the current time value of the register and automatically adjusting the output and control modes of the controller. The fault diagnosis module also comprises a DCS valve position MV; manually setting valve position self-healing upper limit MV SH And manually setting the valve position self-healing lower limit MV SL The range is smaller than the valve position upper limit MV of the DCS system H And DCS system valve position lower limit MV L The method comprises the steps of carrying out a first treatment on the surface of the The variation DeltaSV of the set value; the amount of change Δpv of the measured value; a flag amount C; and a variation threshold M. The fault self-healing module also comprises a DCS valve position MV; a flag amount C; controller calculation CV t The method comprises the steps of carrying out a first treatment on the surface of the Automatic mode AUTO; and a manual mode MAN.
Manually setting valve position self-healing upper limit MV SH And manually setting the valve position self-healing lower limit MV SL The range is smaller than the valve position upper limit MV of the DCS system H And DCS system valve position lower limit MV L And calculating valve position output value and comparing the valve position output value with set upper and lower limit values.
The calculation method comprises the following steps:
the flag amount C is an output of the fault diagnosis module.
MV t+1 With MODE t+1 Is a fault ofThe output of the self-healing module is used for calculating the output and the mode of the controller.
Wherein MV is t Valve position value at time t, CV t+1 Calculating an output value for the t+1 time controller, MV t-1 MV is the valve position value at t-1 t+1 For the valve position at time t+1, MV SH And MV (sum MV) SL The self-healing upper limit and the self-healing lower limit of the valve position are manually set respectively, MV H And MV (sum MV) L The upper limit and the lower limit of the valve position of the DCS system are respectively, deltaSV is the variation of the set value, deltaPV is the variation of the measured value, M is the variation threshold (namely, when the variation amplitude exceeds the value, the fault diagnosis and the self-healing module do corresponding actions), MODE t+1 The mode of the loop at time t+1 (MAN is a manual mode, AUTO is an automatic mode).
As can be seen from the calculation formula, if the valve position at the time t is within the self-healing upper and lower limit range, the valve position output at the time t+1 is used as the calculated output value of the controller; if the valve position value at the time t is within the range between the upper limit and the lower limit of the self-healing and the upper limit and the lower limit of the DCS valve position, the valve position output value at the time t+1 is forcedly arranged in the valve position value at the time t-1 in a register by a fault self-healing module; if the valve position value at the time t is lower than the DCS valve position lower limit or higher than the DCS valve position upper limit, the valve position output value at the time t+1 is forcedly arranged at the valve position value at the time t-1, and the loop mode is forcedly converted into manual Mode (MAN).
Compared with the existing manual adjustment, the invention has the following beneficial effects.
(1) The method obviously reduces the interference of some unpredictable emergencies to the whole device, prevents the interlocking parking which can be avoided by a large device and improves the economic benefit.
(2) The labor intensity of operators is effectively reduced, the problem that the manual mode is needed to be cut off due to the interference of a small period of time is avoided, and the automatic control rate of the device is improved.
In order to verify the effectiveness of the scheme, the simulation verification of the scheme is performed in a certain DCS system by combining with an industrial actual production case. Mainly aims at the following five conditions possibly met in actual production:
in case 1, the operator operates SV by mistake, the SV change exceeds the set threshold M;
case 2, PV fluctuates in a large range due to external interference, and the change amplitude of PV exceeds a threshold M;
in case 3, PV fluctuates in a large range due to external interference, the change amplitude of the PV does not exceed a threshold M, and the change amplitude of the MV exceeds the self-healing upper and lower limits but does not exceed the DCS upper and lower limits;
in case 4, PV fluctuates in a large range due to external interference, the change amplitude of the PV does not exceed a threshold M, and the change amplitude of the MV exceeds the upper and lower limits of the DCS;
case 5, dcs communication or instrumentation causes PV to be constant (including zero).
The diagnosis and self-healing panel is mainly provided with the following parameters: a switching switch, a self-healing upper limit and a self-healing lower limit. Selecting a loop in a certain atmospheric and vacuum device to carry out simulation experiments, and setting self-healing upper and lower limits MV SH 60 MV (MV) SL 40; DCS self valve position limit MV H Is 90 MV L 30. The threshold M is set to 40.
FIG. 4 is a schematic diagram showing the effect of SV adjustment after change of the diagnostic-free self-healing decision maker according to the embodiment of the present invention. As shown, assume the case: if the operator sets the SV by misoperation, the PV and the SV have larger deviation: when the fault diagnosis and fault self-healing module is not put into operation: deviation of PV from SV due to mutation of SV is greatly changed in valve position (MV) by PID regulation. This is caused by misoperation of operators, but the set value is not allowed to change in actual production, so that the interlocking can be triggered.
FIG. 5 schematic of the effect of SV change after addition to the diagnostic self-healing decision maker in case 1. After fault diagnosis and fault self-healing module is put into operation, when SV is in misoperation, the module detects that the change amount of the set value exceeds the set threshold value M, the mark amount C=6, the valve value is set at the value of the last moment, and the controller is directly switched to a Manual (MAN) mode (the process is completed in one machine period, and the actual control valve is not changed).
FIG. 6 is a schematic diagram showing the effect of adjusting the PV of the diagnostic-free self-healing decision maker according to the embodiment of the present invention after fluctuation. As shown in fig. 6, when PV fluctuates widely due to external influences, valve position (MV) also fluctuates widely due to the PID regulation action by the existence of PV and SV deviation. Adversely affecting industrial production.
FIG. 7 is a schematic diagram of the effect of adjusting the PV of case 2 after fluctuation of the PV of the diagnostic self-healing decision maker. When the fault diagnosis and fault self-healing module is thrown (PV change exceeds threshold M), as shown in fig. 7, the PV change is detected to exceed the set threshold M, the flag c=6, the valve value will be set to the last time value and the controller is directly switched to Manual (MAN) mode (this is done in one machine cycle, no change in the actual control valve occurs).
FIG. 8 is a schematic diagram of the effect of regulation after fluctuation of the PV added to the diagnostic self-healing decision maker in case 3. When the fault diagnosis and the fault self-healing module are put in (the change amount of the PV does not exceed the threshold value M, the change of the valve position does not exceed the upper limit and the lower limit of the DCS), as shown in FIG. 8, the mutation of the PV does not exceed the set threshold value M, but the lower limit of the change of the valve position exceeds the lower limit of the self-healing module 40, the mark quantity C=2, and the fault self-healing module acts to place the valve position value (MV) at the last moment value and wait for the elimination of external influences.
FIG. 9 is a schematic diagram of the effect of regulation after fluctuation of the PV added to the diagnostic self-healing decision maker in case 4. When the fault diagnosis and fault self-healing module is put in (the PV variation does not exceed the threshold value M, the valve position variation exceeds the upper and lower limits of DCS itself), as shown in fig. 9, the abrupt change of PV does not exceed the set threshold value M, but at this time the valve position variation lower limit exceeds the DCS lower limit 30, the flag amount c=1, the fault self-healing module acts to place the valve position value (MV) at the last time value and the controller directly switches to Manual (MAN) mode.
FIG. 10 is a schematic diagram showing the effect of the adjustment of the diagnostic-free self-healing decision maker in case 5. When the fault diagnosis and fault self-healing module is not put into operation, as shown in fig. 10, when the PV value is kept unchanged or 0 due to unexpected situations such as communication faults, the valve position is always in an on or off state due to the continuous deviation of PV and SV. The valve position will continue to decrease or rise to the upper and lower limits of the DCS itself. However, in actual production, there is generally no limit to each valve position, and if a problem occurs, the accident is serious.
FIG. 11 is a schematic illustration of the effect of adding a diagnostic self-healing decision maker in case 5. When the fault diagnosis and fault self-healing module is put into operation, as shown in fig. 11, the valve position output value is reduced, when the valve position output value is reduced to the lower self-healing limit, the fault diagnosis module judges that the loop is in an abnormal state, c=2, the valve position output is positioned at the last moment, the valve position output is monitored at the moment in the subsequent adjustment, and the final valve position is controlled at 40%.
According to the simulation experiment, the problems of misoperation of operators, external large interference and large-range fluctuation of the valve position of the control loop caused by system faults are solved by the fault diagnosis and the application of the fault self-healing module, and the subsequent self-healing function of the system is increased.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (2)
1. The fault diagnosis and self-healing system of the control loop is characterized by comprising a controller, wherein the controller is used for receiving set value data and measured value data;
the register stores the output of the controller at the previous moment;
a diagnostic self-healing decision maker configured to receive the controller output and the register output, perform fault diagnosis and self-healing;
the regulating valve is controlled by the diagnosis self-healing decision maker; and
the control object is controlled by the regulating valve;
the diagnostic self-healing decision maker comprises: the fault diagnosis module is configured to judge the numerical range of the current moment output by the controller; the fault self-healing module receives the current time value of the register and automatically adjusts the output and control modes of the controller;
the fault diagnosis module packageThe DCS valve position value MV is included, and the valve position self-healing upper limit MV is manually set SH And manually setting the valve position self-healing lower limit MV SL The range is smaller than the valve position upper limit MV of the DCS system H And DCS system valve position lower limit MV L The change amount DeltaSV of the set value, the change amount DeltaPV of the measured value, the mark amount C and the change threshold M; wherein the fault self-healing module further comprises a controller calculated value CV t An automatic mode AUTO and a manual mode MAN by calculating a valve position output value and comparing the valve position output value with a set upper and lower limit value;
the system further comprises a calculation module, wherein the calculation model is as follows:
wherein the flag quantity C is the output of the fault diagnosis module, CV t+1 Calculating an output value for the t+1 time controller, MV t-1 MV is the valve position value at t-1 t+1 Valve position at time t+1, MODE t+1 Is the mode of the loop at time t+1.
2. A control loop fault diagnosis and self-healing method, comprising:
receiving set value data and measured value data;
judging and outputting the current time numerical range;
receiving the current time value, and automatically adjusting the output and control mode of the controller; and
by calculating the valve position output value and comparing the valve position output value with the set upper and lower limit values,
the calculation method comprises the following steps:
the method comprises the steps of setting a valve position self-healing upper limit MV manually by a DCS valve position value MV SH And manually setting the valve position self-healing lower limit MV SL The range is smaller than the valve position upper limit MV of the DCS system H And DCS system valve position lower limit MV L The controller calculates a value CV from the set value variation DeltaSV, the measured value variation DeltaPV, the flag quantity C, and the variation threshold M t Automatic mode AUTO, and manual mode MAN, with the flag quantity C being the output of the fault diagnosis module, CV t+1 Calculating an output value for the t+1 time controller, MV t-1 MV is the valve position value at t-1 t+1 Valve position at time t+1, MODE t+1 Is the mode of the loop at time t+1.
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