KR20040038124A - A On-line Real-time Operation Performance Monitoring and Diagnostic System for Combined-cycle Power Plant - Google Patents

Abstract

PURPOSE: A system for monitoring and diagnosing operation performance of a combined cycle power plant in real-time through online is effectively store/trace the power plant operation and performance data by using a performance information management system to manage vast performance parameters effectively and systematically in real-time through the online. CONSTITUTION: A DCS(Distributed Control System) layer(1) of each power plant comprises a plurality of power plant distributed control systems. A data obtaining/storing layer(2) comprises a data obtaining/storing system. An online process control/management layer(3) comprises an online process scheduling platform. A performance analysis/diagnosis layer(4) comprises a data validating module(6), a performance analyzing module(7), a compressor cleaning period advisor module(8), a burner burning diagnosis module(9), and a performance diagnosis/alarm module(10). A user interface layer(5) comprises a performance data viewing module that is a GUI(Graphic User Interface) providing various performance information results.

Description

A On-line Real-time Operation Performance Monitoring and Diagnostic System for Combined-cycle Power Plant}

The present invention is to monitor the operation status of the power plant in real time to objectively and quantitatively identify and present the factors that do not operate optimally to maintain the optimal operating performance of the power plant at all times, and to detect the defects of the facility at an early stage to measure the performance of the facility. The present invention relates to an online real-time driving performance monitoring and diagnosis system that can minimize deterioration.

As the domestic and foreign power industry environment has changed drastically, competition in the power generation market has been introduced, and economic efficiency and efficiency are emphasized in terms of power plant operation. In addition, due to the large capacity of power generation facilities and the increase in the number of units of power generation facilities, systematic and efficient facility performance management becomes increasingly difficult. Therefore, application of new operation management techniques is essential.

Conventional combined cycle power plant facilities lack efficient means for efficient performance management, the operation performance optimization is not made effectively, the deterioration of power plant performance, fuel costs and maintenance costs can be said to be somewhat high. In addition, due to the lack of a method for predictive maintenance of the entire power plant and unit equipment, the planned preventive maintenance is performed periodically, resulting in an increase in maintenance costs and a huge loss of power sales due to power generation stoppage.

Conventionally, in an effort to optimally manage operation performance of each unit, life cycle management is performed through the real-time performance monitoring technology for turbines and heat exchangers, which are important facilities of power generation facilities. In addition, some new power plants have the ability to display current operating values in numerical or trend forms on the main control computer. However, the current operating value alone cannot objectively determine whether the plant operating performance is good for the current operating conditions, and can only be subjectively evaluated by some experienced operators.

Prior arts include US Pat. Nos. 5,734,567, 5,913,184, 4,577,270 and 4,967,337. Nos. 5,734,567 and 5,913,184 describe a system consisting of actual data acquisition module, general module, analysis module, knowledge base module and operator module for real-time performance monitoring of heavy turbines in power generation facilities. In addition, it provides the calculated expectations under current operating conditions.

No. 4,577,270 proposes performance diagnosis techniques for optimal operation control of boilers. No. 4,967,337 proposes a kind of knowledge base system called expert system to maintain optimal performance for automated plant equipment. Doing. The above invention mainly proposes a performance diagnosis technique for a unit facility, or it is judged that the applicability and convenience to the combined cycle power plant are somewhat insufficient.

Recently, due to the rapid development of computer technology and information technology, attempts have been made to switch from the method of evaluating and diagnosing the operation performance of power plants to the online real-time method partially.

In the present invention, in order to effectively and systematically manage a large number of performance variables in real time online, the performance real-time operation performance for the combined cycle power to effectively store and track the power plant operation and performance data using the Performance lnformation Management System Its purpose is to provide a monitoring and diagnostic system.

In addition, the present invention constructs a mass and energy balance equation for each facility and the entire power plant of the actual power plant in order to calculate the effective performance parameter value necessary for calculating the actual performance of the power plant, and obtains an effective value satisfying the balance equation based on the measured data. By using it for performance calculation, it is possible to obtain more accurate operating variables and performance analysis values, and to determine whether there is an error in the instrument and to determine whether the instrument needs to be calibrated.

The present invention constructs a performance calculation model using a calibration curve provided by an equipment supplier, a developed correlation, and a conventional performance analysis engine to calculate the actual performance and expected performance of a power plant. By calculating the exact actual performance, expected performance, and rated conversion performance under the current operating conditions, it is possible to provide a function that can objectively and quickly determine the performance degradation of the equipment and the performance degradation of the entire power plant.

The present invention enables operators to take immediate action, thereby maintaining optimal plant operating performance and contributing to enhancing optimal performance management and plant use. In addition, it is possible to maximize the performance of the operation with minimum effort by providing a performance advisor function that can centrally manage the equipment that has a large impact on the comprehensive performance of the combined cycle power plant.

1 is a hierarchical system configuration diagram of the present invention;

2 is a data flow diagram within a system of the present invention;

3 is a data supply and storage screening process diagram,

4 is a system hardware configuration diagram of the present invention.

-Explanation of symbols on main parts of drawing-

1: DCS layer by power plant unit 2: Data acquisition / storage layer

3: On-line Process Control Layer 4: Performance Analysis / True Layer

5: user interface layer 6: data validation module

7: Performance Analysis Module 8: Compressor Cleaning Cycle Expert Module

9: Combustion combustion diagnosis module 10: Performance diagnosis / alarm module

11: Performance data viewing module 12: Actual data communication interface

13-19: Data communication channel 21: Power plant distributed control system (DCS)

The present invention for achieving the above object is a power plant unit-specific DCS layer consisting of a plurality of power plant distributed control system (1); Data acquisition / storage layer (2) of the data acquisition / storage system; online process control management (3) of the online process scheduling platform; A performance analysis / diagnostic layer 4 comprising a data validation module 6 and a performance analysis module 7, a compressor cleaning cycle expert module 8, a combustor combustion diagnostic module 9 and a performance diagnostic / alarm module 10; And a user interface layer 5 of the performance data viewing module 11 as a graphical user interface providing various performance information results; In order to maintain the optimal operating performance of the combined cycle power plant, the operation parameters for each power plant and unit are acquired in real time online to perform the Passion Mountain Analysis, minimizing the effect of performance interference between the facilities and obtaining accurate performance analysis results. It is an integrated real-time operation performance monitoring and diagnosis system that can quantitatively identify the performance degradation of each unit as well as the performance degradation of each facility.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. The present invention is to solve the above-mentioned problem, and will be described in detail the system hierarchy based on FIG.

The present invention is largely composed of five layers, each of which performs an independent function or is organically connected to each other to perform a sequential function. The constituent layer consists of DCS layer (1) by power plant unit, which consists of a plurality of DCS (DCS), data acquisition / storage layer (2) of data acquisition / storage system, and online process control management of online process scheduling platform (3). Performance analysis / diagnostic layer (4) consisting of data validation module (6) and performance analysis module (7), compressor cleaning cycle expert module (8), combustor combustion diagnostic module (9) and performance diagnostic / alarm module (10). And a user interface layer (5) of the performance data viewing module (11) as a graphical user interface (GUI) providing various performance information results.

As shown in FIG. 1, the total calculation flow is actual data on-line in real time from the DCS layer 1 of each power plant distributed control system of the power plant distributed control system that controls the present actual value of the main components of the combined thermal power plant to be monitored. Extract the data to obtain the actual values for performance monitoring and diagnosis. The data acquisition / storage layer (2), which is in charge of the online platform role of this system, extracts and stores the actual data from the power plant distributed control system (DCS) in real time or provides data necessary for performance analysis and calculation of various performance monitoring related modules. Perform the function provided. In addition, it provides the function to effectively store and track huge power plant performance data, and to retrieve the past operation data, and to perform the online data management function to identify the performance degradation by comparing with the current operation data.

Figure 2 schematically shows the flow of data supplied and stored in the performance analysis and diagnostic module through the acquisition and screening process of power plant operation data in the present invention. The data acquisition / storage layer 2 of the data interface 22, the external test 23, the compression test 24, the immediate single-shot data 25, and the data storage 23 includes the power plant distributed control system 21 and its performance. The performance analysis / module / diagnosis module 27 of the analysis / diagnostic layer 4 is connected to each other. In order to minimize the storage capacity of a large amount of data, an exception test 23 and a compression test 24 are used to select only the data that needs to be stored and store it in the data archive 26 to minimize the storage capacity. You can keep the past operation data of.

As shown in FIG. 3, an exception test is performed by comparing a value for a specific tag data with a previous value. If the current data is within a user-defined tolerance band, the value is ignored, and the permission shown in FIG. If out of band 32, the value is immediately sent to Snapshot data 25 for performance analysis and again to compressed data 24 for screening to store in data archive 26. In other words, since the data to be transmitted contains some disturbance, it means that the data is used only when there is a big change in the data. The compression test sets the slope based on the previous two values that passed the exception test 23 and is ignored if the new value is within the allowable slope band, otherwise the old value is stored (34, 35). Again, a new slope is formed based on the two most recent values, and only the data selected through the same test are stored in the archive.

In Fig. 3 (a), there are data points 31 and 32 that passed the exception test within the scope of the user defined exception test, where n is the data point that passed the exception test and immediately entered the single-shot database, and □ does not pass the exception test. The data point could not be ignored. In FIG. 3 (b), there are data points 33 to 36 stored in the data archive 26 by passing the compression test within the validity range of the compression test given by the user, and ■ passes through the compression test and is stored in the data archive. □ does not pass the compression test and is not stored in the data archive.

Next, the online process control management layer 3 is responsible for functions such as data and data format, processor management, and connected processor priority management required from various performance analysis and diagnostic related modules 27.

The data validation module 6 provides a valid value to be used for performance calculation. The data validation module 6 constructs a mathematical equation consisting of material and energy balance equations for each facility and the entire power plant of an actual power plant, and calculates measured data. At the same time, it finds the value closest to the measured data while satisfying the balanced equation. In general, the measured data coming from the instrument is insufficient for proper calibration, lack of maintenance, and sufficient instrumentation to determine the plant status. Can be. Therefore, by applying the same method to calculate the material and energy balance for each facility, not only can you receive values for various variables that are not actually measurable, but also generate more accurate valid data to analyze performance in performance analysis. You can ensure the accuracy of the results.

The performance analysis module (7) is the next step in the calculation of the passionate calculations performed in the data validation module (6) and is provided with a complete data set (Validated value) for the current operating conditions, calculating the expected performance for each plant and the entire power plant. Calculate the corrected value for the reference condition. The performance deterioration of the device is identified by comparing the difference between the exact expected value (target value) of the present operation condition obtained in this module and the actual operation value obtained in the data validation module. In addition, performance degradation can be identified by observing the long-term trend of the corrected value. The modeling method of the performance analysis module (7) is divided into two types according to the components. The gas turbine performance calculation is modeled using the correction curve provided by the supplier and the developed correlation, and the waste heat recovery boiler (HRSC), For condenser, performance analysis engine is used by using manufacturer's design data.

Since the deterioration of gas turbine performance in the combined cycle power plant has a great effect on the overall power plant performance, the gas turbine compressor cleaning cycle specialist (8) and the performance expert module are used to centrally manage the performance of the plant with a large impact on the overall power plant performance. Combustion combustion diagnostic expert (9) Apply the module to increase the optimal performance management. The gas turbine compressor cleaning cycle expert (8) reduces the power generation output and imports due to deterioration of the gas turbine due to the compressor's fouling, the cleaning cost due to the compressor cleaning, and the decrease in power sales revenue due to the gas turbine shutdown in the case of off-line cleaning. This module decides the optimum compressor cleaning time and period.

Combustor combustion expert module (9) is a module for monitoring / diagnosing the combustion state of gas turbine combustor by monitoring the gas turbine exhaust temperature pattern, and combustion state monitoring is performed by using various thermometers and annular thermometer points installed in the gas turbine exhaust port. Under the conditions, the combustion temperature of the combustor is diagnosed by detecting the deviation from the reference temperature trace by comparing the current exhaust temperature pattern based on the annular temperature trace of the optimum combustion state.

In the power plant performance status diagnosis module (10), a diagnostic tree that presents the main causes and solutions of problems in case of abnormal symptoms of power plant operating variables (main steam low pressure, multiple gas high pressure, gas exhaust gas high temperature, and multiple gas hotwell and cooling). By providing the Diagnosis Tree, the problem can be solved quickly and easily, contributing to maintaining the power plant performance optimally.

The results of all of these series of analysis modules are sent back to the data acquisition / storage layer (2) and stored using the data communication channels (13-l9), thereby automatically constructing plant performance information. It is also possible to conveniently extract and use performance information when reading or writing performance reports.

The performance analysis information using the combined thermal power online operation performance monitoring and diagnosis system can be easily accessed and viewed by plant workers or managers, and is installed and operated under the latest network environment to improve utilization and utilization rate. Hardware is configured to have client / server structure.

As shown in Figure 4, by connecting this system to the power plant network (TCP / IP), it is possible to view the power plant performance information in real time from the plant workers as well as outside. In addition, the graphical user interface (CUI) provides performance status screens and performance reports in various graphs or process diagrams to help understand the plant's performance and to implement a user-friendly system.

The performance monitoring server 42 is connected to the buffer node computer 41 of the control room to which the power plant distributed control system 21 is connected via Ethernet TCP / IP, and the performance monitoring server 42 is connected to the power plant network (TCP / IP). As a client personal computer, the administrator computer 43, the maintenance computer 44, the operator computer 45, and the efficiency source computer 46 are connected to each other, thereby providing a combined thermal online real-time driving performance monitoring and diagnosis system server. In conjunction with the power plant network, it has a server / client structure that allows operators, performance managers, maintenance staff and administrators to view performance information from their computers with ease.

The real-time operation performance monitoring and diagnosis system does not use the actual site data (from the instrument) for the real-time performance monitoring through accurate and reliable performance analysis, and takes into account the uncertainty of each operation variable by considering the uncertainty of each instrument. In addition, it satisfies the enthusiasm of the unit and the entire power plant, and generates an effective value that minimizes the objective function of the following minimum method.

The objective function of the least-squares method is ∑ (V-M) ² / UC², where UC is the actual data uncertainty, V is the effective value obtained through the Passion Module, and M is the measured value from the field instrument.

On-line real-time operation performance monitoring and diagnosis system applying the performance monitoring index is a method of quantitatively identifying the deterioration of performance. In addition to the evaluation, the operating conditions and atmospheric conditions are monitored by monitoring the performance trend over a long period of time by applying the accurate conversion of the current valid values for the current operating conditions into the design conditions of the facility and the reference conditions, which are the operating conditions when the initial performance is acquired. We can evaluate the absolute performance without the effect of

The present invention is a system that can provide the operational performance monitoring and diagnosis results of the entire power plant and unit facilities in real time through the online method during operation, to present the real-time performance evaluation, performance degradation monitoring and performance improvement plan of the combined cycle power plant Can be.

As the transition from the conventional online method or manual evaluation of power plant operating performance to online real-time method can be continuously monitored, performance deterioration can be minimized by early detection and action of equipment defect In addition, it is possible to systematically and quickly evaluate the performance of the facility, thereby ensuring the soundness of the facility and improving the efficiency of the facility operation.

In addition, it is possible to determine the maintenance cycle according to the degree of performance deterioration of the equipment, apart from the conventional periodic maintenance, and the maintenance cycle can be made longer, thereby improving the use of the power generation equipment by shortening the power plant stoppage for regular maintenance. Maintenance cost can be reduced.

By establishing a server / client structure in connection with this system and the power plant network, power plant operator, performance staff and management can conveniently and freely view the power plant operating performance information from their personal computer. Can make good decisions.

Claims (5)

DCS layer (1) of the power plant unit by a plurality of power plant distributed control system; A data acquisition / storage layer 2 of the data acquisition / storage system; Online process control management (3) of the online process scheduling platform; A performance analysis / diagnostic layer 4 comprising a data validation module 6 and a performance analysis module 7, a compressor cleaning cycle expert module 8, a combustor combustion diagnostic module 9 and a performance diagnostic / alarm module 10; And a user interface layer 5 of the performance data viewing module 11 as a graphical user interface providing various performance information results; In order to maintain the optimal operating performance of the combined cycle power plant, the operation parameters for each power plant and unit are acquired in real time online to perform the Passion Mountain Analysis, minimizing the effect of performance interference between the facilities and obtaining accurate performance analysis results. Integrated real-time operation performance monitoring and diagnosis system that can quantitatively identify the performance degradation of each unit as well as the performance degradation of each facility variable. The method of claim 1, The performance analysis / advanced layer 4 does not use the actual plant field measurement data from the power plant for real-time performance monitoring through accurate and reliable performance analysis, and considers the measurement values of all operating variables by considering the uncertainty of each instrument. Gives uncertainty and satisfies the passion mountain of the unit and the entire power plant, while the objective function of the least-privileged law is: M: Real-time operation performance monitoring and diagnosis system that generates effective value that is the minimum value from the field instrument and uses it for performance calculation and analysis. The method of claim 1, The performance analysis module (7), in the method of quantitatively identifying the deterioration of performance, compares and monitors the current operating performance by comparing and monitoring the accurate current operating validity value and the expected value with respect to the current operating condition, It is possible to evaluate the absolute performance excluding the influence of the operating and atmospheric conditions by monitoring the performance trend over a long period of time by applying the accurate conversion value converted from the exact current effective value into the design condition of the facility and the reference condition, which is the operating condition when the initial performance is acquired. Online real-time operation performance monitoring and diagnosis system applying performance monitoring index. The method of claim 1, A power plant distributed control system 21 includes a data interface 22, an external test 23, a compression test 24, an immediate single-shot data 25, and a data recording / receiving layer 2 comprising a data recording 23. And the performance analysis / module / diagnosis module 27 of the performance analysis / diagnostic layer 4 are respectively connected; In order to minimize the storage capacity of a large amount of data, the exception test 23 and the compression test 24 select only the data that needs to be stored and store it in the data archive 26 to minimize the storage capacity to store long-term past operation data. On-line real-time operation performance monitoring and diagnostic system for combined cycle power. The performance monitoring server 42 is connected to the buffer node computer 41 of the control room to which the power plant distributed control system 21 is connected via Ethernet TCP / IP, and the performance monitoring server 42 is connected to the power plant network (TCP / IP). An administrative computer 43, a maintenance computer 44, an operator computer 45 and an efficiency source computer 46 are respectively connected as client personal computers; Combined cycle online real-time operation performance monitoring and diagnostic system server in conjunction with the power plant network, operators, performance managers, maintenance staff and administrators can conveniently view the performance information on their computer, characterized in that the online real-time operation performance for combined cycle Surveillance and Diagnosis System.