Instrument control equipment virtual maintenance method based on DCS parallel system

Abstract

The invention belongs to the technical field of nuclear power plant instrument control maintenance, and particularly relates to an instrument control equipment virtual maintenance method based on a DCS parallel system. Selecting DCS equipment maintenance regulations, performing equipment virtual maintenance in the control cabinet three-dimensional model of the DCS parallel system, starting the DCS parallel system, resetting initial conditions under a full power condition, and operating; according to the selected DCS equipment maintenance regulation, DCS equipment related to the regulation is carried out, and virtual tool preparation is carried out in a DCS parallel system; performing virtual maintenance on the virtual three-dimensional cabinet model of the DCS parallel system according to maintenance work implementation steps in the selected DCS equipment maintenance procedure, and verifying operation steps of the procedure; according to maintenance procedure risks and errors identified in the virtual maintenance process, improvement measures are put forward, and then verification is carried out in a DCS parallel system. Virtual drilling of the DCS equipment maintenance process is achieved, maintenance personnel are familiar with the maintenance process, the DCS maintenance proficiency and emergency handling capacity of the nuclear power plant are improved, and the DCS maintenance efficiency and effect are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of nuclear power plant I&C maintenance, and particularly relates to a virtual maintenance method for I&C equipment based on a DCS parallel system. Background Art

[0002] With the development of digital I&C technology, the Distributed Control System (DCS) has been widely used in nuclear power plants due to its characteristics such as distributed control and centralized monitoring, and the control process is reliable and stable. The DCS system brings many conveniences and advantages to the operation and maintenance of I&C professionals and equipment management of nuclear power units, and at the same time greatly increases the complexity of maintenance.

[0003] In order to ensure the accuracy and efficiency of the DCS maintenance process and avoid the operation risks of the unit caused by maintenance, nuclear power plant maintenance personnel often need to verify the maintenance plan. Currently, the maintenance plan is usually verified by maintenance personnel through experiments on a small-scale DCS physical control cabinet or by industry experts. Since the scale of the DCS physical control cabinet used for plan verification is small, the types of equipment are limited, and there is no feedback signal to form a control closed-loop, the maintenance plan verification scenarios that can be provided are relatively few, and dynamic visual plan verification cannot be achieved. The efficiency and effect of the maintenance plan verification are not good. Summary of the Invention

[0004] The purpose of the present invention is to provide a virtual maintenance method for I&C equipment based on a DCS parallel system, which realizes virtual rehearsal of the DCS equipment maintenance process, can verify the feasibility of the DCS equipment maintenance plan, enables maintenance personnel to be familiar with the maintenance process, is beneficial to improving the proficiency of DCS maintenance in nuclear power plants and the ability to handle emergencies, and improves the efficiency and effect of DCS maintenance.

[0005] To achieve the above object, the technical solution adopted by the present invention is as follows:

[0006] A virtual maintenance method for I&C equipment based on a DCS parallel system. Select the DCS equipment maintenance regulations, perform virtual maintenance of the equipment in the 3D model of the control cabinet of the DCS parallel system, start the DCS parallel system, reset the initial conditions under full power and run; according to the selected DCS equipment maintenance regulations, perform the DCS equipment involved in the regulations, and prepare virtual tools in the DCS parallel system; according to the maintenance work implementation steps in the selected DCS equipment maintenance regulations, perform virtual maintenance on the virtual 3D cabinet model of the DCS parallel system to verify the operation steps of the regulations; according to the risks and errors of the maintenance regulations identified in the virtual maintenance process, propose improvement measures, and then verify in the DCS parallel system.

[0007] The specific steps are as follows:

[0008] Step 1: Select the DCS equipment maintenance regulation "Controller Layer CPU Module Replacement Procedure", start the DCS parallel system, reset the initial conditions under full power, and run it.

[0009] Step 2: Work preparation: According to the selected DCS equipment maintenance regulation "Controller Layer CPU Module Replacement Procedure", analyze the DCS equipment involved in this regulation, and prepare virtual tools in the DCS parallel system.

[0010] Step 3: According to the work implementation steps in the selected DCS equipment maintenance regulation "Controller Layer CPU Module Replacement Procedure", operate on the virtual 3D model of the DCS control cabinet in the DCS parallel system to verify the operation steps of this regulation.

[0011] Step 4: Based on the virtual maintenance process of controller replacement in the DCS parallel system and the operating status of the unit, judge the feasibility of the "Controller Layer CPU Module Replacement Procedure"; if no risks are generated, proceed to Step 6, and if risks are generated, proceed to Step 5.

[0012] Step 5: According to the relevant risk factors generated by virtual maintenance in the DCS parallel system, analyze and propose corrective measures, implement them in the DCS parallel system, and return to Step 2 to re-operate to verify the effectiveness of the corrective measures.

[0013] Step 6: Based on the process of virtual maintenance of DCS equipment in the DCS parallel system and the verification of corrective measures, compile a verification report to provide operation guidance for the verification of DCS maintenance regulations.

[0014] The specific steps of Step 3 are as follows:

[0015] Step 301: Prepare before work and conduct risk analysis.

[0016] Step 302: Remove the CPU module to be replaced in the 3D model of the control cabinet in the DCS parallel system: According to the operation steps of the replacement procedure, remove the CPU module as required, and observe whether it affects the operating status of the unit in the DCS parallel system. If it does not affect the operating status of the unit, proceed to the next step.

[0017] Step 303: Install the spare CPU module in the 3D model of the control cabinet in the DCS parallel system: According to the operation steps of the replacement procedure, install the spare CPU module as required, and observe whether it affects the operating status of the unit in the DCS parallel system. If it does not affect the operating status of the unit, proceed to the next step.

[0018] Step 304: Confirm the status of the replaced CPU module: According to the operation steps of the replacement procedure, confirm that the replaced module works properly in the DCS parallel system, then reset the cabinet alarm, restore the site, and end the work.

[0019] Step 301: Communicate with the main controller to inform the list of devices that may lose display and control.

[0020] Before the work is carried out, record the status of the operation modules involved in the DCS parallel system. After the controller status is restored, check and restore it in a timely manner.

[0021] Step 5: The relevant risk factors include causing misoperation of process equipment.

[0022] Step 5: The corrective measures include switching the process equipment to the local control state in advance, or locking the relevant protection interlocks through temporary control changes.

[0023] Step 2: The tools prepared are as follows: 3 screwdrivers, 1 flashlight, and 1 spare CPU module.

[0024] The three-dimensional model of the control cabinet of the DCS parallel system can be replaced by the physical cabinet of the DCS parallel system.

[0025] The beneficial effects obtained by the present invention are as follows:

[0026] The present invention can verify the feasibility of the maintenance procedures and enable maintenance personnel to quickly familiarize themselves with the maintenance process in a realistic scenario, which is beneficial to improving the skills of maintenance personnel and reducing maintenance risks. Description of the Drawings

[0027] Figure 1 It is a composition diagram of a virtual maintenance method for instrument control equipment based on the DCS parallel system;

[0028] Figure 2 It is a flowchart of a virtual maintenance method for instrument control equipment based on the DCS parallel system;

[0029] Figure 3 It is a flowchart of an embodiment of a virtual maintenance method for instrument control equipment based on the DCS parallel system. Detailed Embodiment

[0030] The present invention will be described in detail below with reference to the drawings and specific embodiments.

[0031] The technical solution of the present invention is to perform virtual maintenance of DCS instrumentation and control equipment based on the DCS parallel system of a nuclear power plant. The DCS parallel system of a nuclear power plant is a digital twin system of the DCS of a nuclear power plant established using instrumentation and control technology and simulation technology. The system includes a DCS virtual controller model for the entire plant, a number of DCS physical control cabinets, a three-dimensional virtual simulation model of all DCS control cabinets of the unit, a unit process system model, a DCS second-layer system, and related communication software. The DCS parallel system includes a DCS fault simulation model, which can be used to drill and verify the DCS maintenance plan based on the virtual simulation model of the DCS control cabinet, and visualize the impact of DCS maintenance on the operation of the unit based on the DCS parallel system. The method of the present invention relies on the DCS parallel system of a nuclear power plant, and according to the corresponding maintenance procedures of the DCS, based on the three-dimensional virtual simulation model of the DCS control cabinet in the DCS parallel system, performs virtual maintenance drills for DCS equipment, thereby accurately and quickly verifying the DCS equipment maintenance plan and mastering maintenance skills.

[0032] Select the DCS equipment maintenance procedure and perform virtual maintenance of the equipment in the three-dimensional model of the DCS control cabinet of the DCS parallel system. This allows you to quickly verify the maintenance plan and master maintenance skills. Select the DCS equipment maintenance procedure, start the DCS parallel system, reset the initial conditions under full power and run it. According to the selected DCS equipment maintenance procedure, perform the DCS equipment involved in the procedure and prepare virtual tools in the DCS parallel system. Perform virtual maintenance on the virtual three-dimensional cabinet model of the DCS parallel system according to the maintenance work implementation steps in the selected DCS equipment maintenance procedure to verify the operation steps of the procedure. Based on the maintenance procedure risks and errors identified during the virtual maintenance process, propose improvement measures, and then verify them in the DCS parallel system.

[0033] Step 1: Select the DCS equipment maintenance procedure "Controller layer CPU module replacement procedure", start the DCS parallel system, reset the initial conditions under full power, and run it.

[0034] Step 2: Work preparation: According to the selected DCS equipment maintenance regulations "Controller layer CPU module replacement procedure", analyze the DCS equipment involved in the regulations, and prepare virtual tools in the DCS parallel system. The prepared tools are as follows: 3 screwdrivers, 1 flashlight, and 1 spare CPU module.

[0035] Step 3: According to the work implementation steps in the selected DCS equipment maintenance procedure "Controller Layer CPU Module Replacement Procedure", operate in the virtual 3D model of the DCS control cabinet of the DCS parallel system to verify the operating steps of the procedure.

[0036] The present invention proposes to perform virtual maintenance of DCS equipment in a DCS parallel system to verify the feasibility of the maintenance procedures of DCS equipment. The specific steps are as follows:

[0037] Step 301: Preparation before work, with a focus on conducting risk analysis:

[0038] Risk analysis description: In theory, the controller adopts a redundant configuration. When replacing one of them, it will not affect the system. However, it cannot be excluded that both redundant controllers go offline during the replacement of the faulty controller, which affects the status display of the corresponding equipment and the issuance of operator instructions. And when both redundant controllers fail and go offline, the code needs to be reinstalled, which takes a certain amount of time to recover.

[0039] After both redundant controllers are restarted after going offline, it may affect some start / stop, switch, and manual / automatic commands. Special risk considerations are required, such as considering the risk that the process equipment controlled by this controller may malfunction.

[0040] Preventive measures: Communicate with the main control personnel and inform the list of equipment that may lose display and control.

[0041] Before starting work, record the status of the operation modules (SLC, Select block, etc.) involved in the DCS parallel system described in the present invention. After the controller status is restored, check and restore it in a timely manner.

[0042] Step 302: Remove the CPU module to be replaced in the 3D model of the control cabinet of the DCS parallel system described in the present invention: According to the operation steps of the replacement procedure, remove the CPU module as required, and observe whether it affects the unit operation status in the DCS parallel system described in the present invention. If it does not affect the unit operation status, proceed to the next step.

[0043] Step 303: Install the spare CPU module in the 3D model of the control cabinet of the DCS parallel system described in the present invention: According to the operation steps of the replacement procedure, install the spare CPU module as required, and observe whether it affects the unit operation status in the DCS parallel system described in the present invention. If it does not affect the unit operation status, proceed to the next step.

[0044] Step 304: Confirm the status of the replaced CPU module: According to the operation steps of the replacement procedure, confirm that the replaced module works properly in the DCS parallel system described in the present invention, then reset the cabinet alarm, restore the site, and end the work.

[0045] Step 4: Based on the virtual maintenance process of the controller replacement in the DCS parallel system described in the present invention and the operation status of the unit, judge the feasibility of the "Controller Layer CPU Module Replacement Procedure". If no risk is generated, proceed to Step 6; if a risk is generated, proceed to Step 5.

[0046] Step 5: Analyze and propose corrective measures based on the relevant risk factors generated by virtual maintenance in the DCS parallel system described in the present invention, such as causing malfunction of process equipment, etc. For example, switch the process equipment to the local control state in advance, or lock out relevant protection interlocks through temporary control changes, implement them in the DCS parallel system, and return to Step 2 to perform the operation again to verify the effectiveness of the corrective measures.

[0047] Step 6: Compile a verification report based on the process of virtual maintenance of DCS equipment and the verification of corrective measures in the DCS parallel system described in the present invention to provide operation guidance for the verification of the DCS maintenance procedures.

[0048] It should be particularly noted that the virtual maintenance of DCS equipment in the DCS parallel system mentioned in the method of the present invention is implemented by using the three-dimensional model of the control cabinet in the DCS parallel system in Step 3 of this embodiment. In addition to this method, the DCS equipment can also be maintained according to the method mentioned in the present invention in the physical DCS cabinet of the DCS parallel system described in the present invention. Therefore, the virtual maintenance of DCS equipment using the physical DCS cabinet of the DCS parallel system is also within the scope of the method of the present invention.

Claims

1. A virtual maintenance method for instrument control equipment based on a DCS parallel system, characterized in that: Select the DCS equipment maintenance regulations, perform virtual maintenance of the equipment in the 3D model of the control cabinet of the DCS parallel system, start the DCS parallel system, reset the initial conditions under full power and run; according to the selected DCS equipment maintenance regulations, perform the DCS equipment involved in this regulation, and prepare virtual tools in the DCS parallel system; according to the maintenance work implementation steps in the selected DCS equipment maintenance regulations, perform virtual maintenance on the virtual 3D cabinet model of the DCS parallel system to verify the operation steps of this regulation; according to the risks and errors of the maintenance regulations identified in the virtual maintenance process, propose improvement measures, and then verify in the DCS parallel system.

2. The virtual maintenance method for instrument control equipment based on a DCS parallel system according to claim 1, characterized in that: The specific steps are as follows: Step 1: Select the DCS equipment maintenance regulation "Controller Layer CPU Module Replacement Procedure", start the DCS parallel system, reset the initial conditions under full power, and run; Step 2: Work preparation: Analyze the DCS equipment involved in this regulation according to the selected DCS equipment maintenance regulation "Controller Layer CPU Module Replacement Procedure", and prepare virtual tools in the DCS parallel system; Step 3: According to the work implementation steps in the selected DCS equipment maintenance regulation "Controller Layer CPU Module Replacement Procedure", operate on the virtual 3D model of the DCS control cabinet in the DCS parallel system to verify the operation steps of this regulation; Step 4: Based on the virtual maintenance process of controller replacement in the DCS parallel system and the operating status of the unit, judge the feasibility of the "Controller Layer CPU Module Replacement Procedure"; if no risks are generated, proceed to Step 6, if risks are generated, proceed to Step 5; Step 5: Analyze and propose corrective measures according to the relevant risk factors generated during virtual maintenance in the DCS parallel system, implement them in the DCS parallel system, and return to Step 2 to perform the operation again to verify the effectiveness of the corrective measures; Step 6: Compile a verification report based on the process of virtual maintenance of DCS equipment in the DCS parallel system and the verification of corrective measures, and provide operation guidance for the verification of DCS maintenance regulations.

3. The virtual maintenance method for instrument control equipment based on a DCS parallel system according to claim 2, characterized in that: The specific steps of Step 3 are as follows: Step 301: Prepare before work and perform risk analysis work; Step 302: Remove the CPU module to be replaced in the 3D model of the control cabinet of the DCS parallel system: According to the operation steps of the replacement procedure, remove the CPU module as required, and observe whether it affects the operating status of the unit in the DCS parallel system. If it does not affect the operating status of the unit, proceed to the next step; Step 303: Install the spare CPU module in the 3D model of the control cabinet of the DCS parallel system: According to the operation steps of the replacement procedure, install the spare CPU module as required, and observe whether it affects the operating status of the unit in the DCS parallel system. If it does not affect the operating status of the unit, proceed to the next step; Step 304: Confirm the status of the replaced CPU module: According to the operation steps of the replacement procedure, confirm that the replaced module works properly in the DCS parallel system, then reset the cabinet alarm, restore the site, and end the work.

4. The virtual maintenance method for I&C equipment based on the DCS parallel system according to claim 3, wherein: Step 301: Communicate with the main control personnel to inform the list of equipment that may lose display and control; before starting the work, record the status of the operation modules involved in the DCS parallel system, and after the controller status is restored, check and restore in a timely manner.

5. The virtual maintenance method for I&C equipment based on the DCS parallel system according to claim 2, wherein: Step 5: The relevant risk factors include causing the process equipment to malfunction.

6. The virtual maintenance method for I&C equipment based on the DCS parallel system according to claim 5, wherein: Step 5: The corrective measures include switching the process equipment to the local control state in advance, or locking the relevant protection interlocks through temporary control changes.

7. The virtual maintenance method for I&C equipment based on the DCS parallel system according to claim 2, wherein: Step 2: Prepare the following tools: 3 screwdrivers, 1 flashlight, and 1 spare CPU module.

8. The virtual maintenance method for I&C equipment based on the DCS parallel system according to claim 1, wherein: The three-dimensional model of the control cabinet of the DCS parallel system can be replaced by the physical cabinet of the DCS parallel system.

Images