A method for improving the reliability of DCS system modules of power station generator sets

Abstract

A method for improving the reliability of a DCS system module of a power station generator set belongs to the field of control. For the internal communication module and I / O input / output module of the DCS system of the generator set, the existing system architecture and hardware are retained, and the module containing the FPGA chip is subjected to ECC error checking and correction verification import to realize the automatic error correction function; the signal function of the I / O input / output module is analyzed, and if a single I / O input / output module failure may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules to effectively reduce the adverse effects of a single module failure on the safe operation of the unit; through the above steps, the probability of module failure caused by the FPGA chip of the DCS system module of the generator set due to the influence of high-energy neutron radiation is reduced, and the operating reliability of the DCS system and the generator set is improved. It is suitable for the operation, maintenance or reconstruction of the DCS system of the power station generator set.

Description

[0001] Technical solution areas

[0002] The invention belongs to the field of automatic power generation control, and in particular relates to a method for improving the reliability of a DCS system module of a power station generator set.

[0003] Background technology solution

[0004] DCS (Distributed control system), also known as distributed control system, is a multi-level computer system composed of process control level and monitoring level with communication network as the link. Its basic concept is decentralized control and centralized monitoring. Due to its strong versatility, complete functions and safe and reliable operation, it has been widely used in power station generators.

[0005] The DCS system hardware of the generator set is mainly composed of the central processing unit (CPU) control unit, various modules and network equipment, etc., to realize the monitoring of the boiler, steam turbine, generator and various environmental protection and public auxiliary equipment of the generator set. The various modules mainly include communication modules, I / O input and output modules, etc. For generator sets with an installed capacity of more than 300MW, the total number of modules generally exceeds 1,000. The various modules of the DCS system of the power station generator set are composed of electronic components and integrated circuits, which generally include FPGA chips.

[0006] FPGA (Field-Programmable Gate Array) is a type of semiconductor device integrated circuit. It is mainly used to configure the logic designed by application software. FPGA adopts a structure similar to a gate array, has rich logic resources, is reprogrammable, and has superior performance. It is widely used in modern electronic products.

[0007] As we all know, semiconductor device integrated circuits are susceptible to radiation, which mainly comes from natural radiation (also known as galactic cosmic rays), including the influence of the sun and the universe. Galactic cosmic rays refer to alpha particles (composed of neutrons and protons), heavy ions and protons from space, while the sun mainly emits electrons, protons and heavy ions. Neutrons are very small and can easily pass through the atmosphere and even the entire earth. Moreover, since they have no charge, they can escape the radiation belt trap of the earth. Therefore, the particles that reach the ground and act on semiconductors are mainly neutrons. Radiation is mainly divided into two categories: ionizing and non-ionizing. Semiconductor devices are greatly affected by ionizing radiation. Ionizing radiation caused by particles (such as high-energy neutrons) is the most common in daily applications.

[0008] With the continuous advancement of semiconductor technology, the integration, functions and performance of embedded systems are increasing. The density of components such as transistors and capacitors in integrated circuits has also greatly increased. The size of components has become smaller, making them more susceptible to radiation, and the failure rate caused by radiation is also higher.

[0009] FPGA itself is also a static memory. The radiation effect of high-energy neutrons in the atmosphere or radioactive materials mainly affects data (soft error). Soft error means that the data in the memory unit or register is changed (binary data 1 becomes 0 or 0 becomes 1), but the memory unit is not damaged. Generally, a single bit is affected, and occasionally more than one bit is affected. Soft errors will change the data in the FPGA memory unit, causing a single or multiple bits to flip, thereby causing the module containing the FPGA chip to malfunction, and the DCS system module that undertakes the main equipment monitoring function of the generator set to malfunction, which brings great risks to the safe and stable operation of the DCS system and the generator set.

[0010] FPGA is widely used in various modules of the DCS system of power station generator sets. A generator set with an installed capacity of more than 300MW contains thousands of FPGA modules. For a single FPGA, the probability of data flipping due to the above-mentioned radiation is very low. According to statistics from a well-known FPGA manufacturer, it is about once every 240 years. However, when the number of FPGA modules in the DCS system of a generator set is as many as thousands, the module failure caused by such anomalies occurs more than ten times a year on average, posing a great hidden danger to the safe and stable operation of the DCS system and the generator set. For example, after the DCS system input / output (I / O) module fails, the output signal of the output module will be set to 0 from the current value, causing the field equipment driven by it to malfunction; after the communication module fails, it will lose normal communication function. If there is no redundant configuration and other measures, it may directly lead to DCS system communication failure and unit shutdown.

[0011] Since data in semiconductor device integrated circuits such as FPGAs may undergo unexpected data changes during transmission and storage due to radiation (such as the high-energy neutron radiation mentioned above), data verification is generally used to ensure the integrity and accuracy of the data. Commonly used methods include parity check (Parity Check) and CRC (Cyclical Redundancy Check) cyclic redundancy check to detect whether the data is wrong, but these two verification methods can only detect errors but do not have error correction functions.

[0012] How to effectively reduce the probability of module failure caused by radiation affecting the FPGA chip in the DCS system module of the power station generator set, improve the reliability of the DCS system module of the power station generator set, and ensure the safe and stable operation of the DCS system and the generator set, is a practical technical solution problem that urgently needs to be solved in actual work. Summary of the invention

[0013] The technical solution to be solved by the present invention is to provide a method for improving the reliability of the DCS system module of the power station generator set. The method realizes the automatic error correction function by performing ECC error checking and correction check import on the module containing the FPGA chip in the DCS system of the generator set, reduces the probability of module failure caused by the FPGA chip of the DCS system module of the generator set being affected by high-energy neutron radiation, and improves the operating reliability of the DCS system and the generator set.

[0014] The technical solution of the present invention is to provide a method for improving the reliability of a DCS system module of a power station generator set, which is characterized by:

[0015] The first step is to keep the existing DCS system architecture and hardware that have been put into production and use unchanged for the DCS system internal communication modules and I / O input and output modules that contain FPGA chips in the DCS system of the generator set. Only when the unit is shut down for maintenance, ECC error check and correction verification are carried out on the modules containing FPGA chips to realize automatic error correction function.

[0016] The second step is to analyze the signal functions of the I / O input / output modules. If a single I / O input / output module failure may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules to effectively reduce the adverse effects of a single module failure on the safe operation of the unit.

[0017] The method for improving the reliability of the DCS system module of the power station generator set reduces the probability of module failure caused by the FPGA chip of the DCS system module of the generator set being affected by high-energy neutron radiation through the above steps, thereby improving the operating reliability of the DCS system and the generator set.

[0018] Specifically, the ECC error check and correction verification import of the module including the FPGA chip includes erasing the original data in the firmware storage area of ​​the flash memory in the FPGA chip, maintaining the data in other storage areas unchanged, and then importing the ECC function to realize the update of the data in the flash memory firmware storage area.

[0019] Furthermore, the method for improving the reliability of the DCS system module of the power station generator set is to add an ECC error checking and correction check function to the DCS system module for single-bit data errors, replacing the original CRC cyclic redundancy check that can only detect errors but cannot automatically correct them, and realizing the automatic error correction function.

[0020] Furthermore, the method for improving the reliability of the DCS system module of the power station generator set is to sort out the signals and analyze the functions of the I / O input and output modules for the problem of module failure caused by two or more bit data errors. If the failure of a single I / O input and output module may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules, thereby effectively reducing the adverse effects of a single module failure on the safe operation of the unit.

[0021] Specifically, for the module that includes the FPGA chip, if an error occurs in only one bit of the data, the ECC error check and correction verification automatically corrects the error in this bit, so that the function of the module is not affected and maintains normal operation; if an error occurs in two or more bits of data, the ECC error check and correction verification will notify the CPU control unit that a data error has occurred.

[0022] Specifically, the ECC error checking and correction verification importing of the module including the FPGA chip at least includes importing the ECC error checking and correction verification function into the communication module and importing the ECC error checking and correction verification function into the I / O input and output module.

[0023] Furthermore, the introduction of ECC error checking and correction checking function into the communication module at least comprises the following steps:

[0024] (1) Unplug each communication module from the DCS system and insert it into the maintenance card slot equipped with power supply. Connect the maintenance computer and the communication module with the communication cable;

[0025] (2) Using the software tool on the maintenance computer and the read-back function, read all the data from the flash memory of the FPGA chip in the communication module and store it in the computer;

[0026] (3) Erase the original data in the firmware storage area of ​​the flash memory in the FPGA chip, and keep the data in other storage areas unchanged;

[0027] (4) Importing the data of the ECC error checking and correction function into the firmware storage area of ​​the flash memory in the FPGA chip;

[0028] (5) All data in the flash memory of the FPGA chip into which the new data has been imported are read back to the maintenance computer and stored;

[0029] (6) Compare all the flash memory data read twice to confirm that the data in the firmware storage area is updated correctly and other data in the non-firmware storage area remains unchanged;

[0030] (7) The communication module completes the ECC error checking and correction verification function import.

[0031] Furthermore, the introduction of ECC error checking and correction checking function to the I / O input and output module at least includes the following steps:

[0032] (1) The DCS system CPU control unit corresponding to the I / O input and output module group is disabled;

[0033] (2) Communication cable connects the maintenance computer and the I / O communication module;

[0034] (3) Importing software tools and I / O module input and output configuration files into the I / O communication module;

[0035] (4) The I / O input and output module is powered off and then powered on again to restart the module;

[0036] (5) Importing data of the group of I / O input and output modules in sequence;

[0037] (6) Automatically identify the type and data version of the first I / O input / output module, and use the read-back function to read and store all the data in the flash memory of the FPGA chip in the first module I / O input / output module;

[0038] (7) Erase the original data in the firmware storage area of ​​the flash memory in the FPGA chip, and keep the data in other storage areas unchanged;

[0039] (8) Importing the data of the ECC error checking and correction function into the firmware storage area of ​​the flash memory in the FPGA chip;

[0040] (9) Read back and store all the data in the flash memory of the FPGA chip into which the new data has been imported;

[0041] (10) Compare all the flash memory data read twice to confirm that the data in the firmware storage area is updated correctly and other data in the non-firmware storage area remains unchanged;

[0042] (11) The first I / O input / output module of the group completes the ECC error checking and correction check function introduction;

[0043] (12) The software tool repeats steps (6) to (11) above to complete the introduction of the ECC error checking and correction check function for the 2nd to 8th I / O input and output modules of the group;

[0044] (13) Repeat the above steps (1) to (12) to complete the introduction of ECC error checking and correction check functions for all groups of I / O input and output modules.

[0045] The method for improving the reliability of the DCS system module of the power station generator set of the present invention effectively reduces the probability of module failure caused by the FPGA chip in the DCS system module of the power station generator set being affected by radiation, improves the reliability of the DCS system module of the power station generator set, and ensures the safe and stable operation of the DCS system and the generator set.

[0046] Compared with the prior art solutions, the advantages of the present invention are:

[0047] 1. This technical solution implements the one-bit data automatic error correction and two-bit data error detection functions of the module containing the FPGA chip by introducing the ECC error check and correction check function into the module containing the FPGA chip in the DCS system, which can effectively reduce the probability of module failure caused by radiation influence of the FPGA chip in the DCS system module of the power station generator set, and improve the working reliability of the DCS system module of the power station generator set;

[0048] 2. The implementation of the entire technical solution does not involve changes to the architecture and hardware of the existing DCS system. It is highly feasible, low in cost, short in time and has obvious effects.

[0049] 3. When implementing this technical solution, it only takes the opportunity of shutting down the unit for maintenance, which can be completed in a short time. It will not affect the normal operation and power generation of the unit, avoid power generation losses, and effectively reduce the adverse effects of a single module failure on the safe operation of the unit. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 This is a schematic diagram of hardware configuration connection for introducing ECC check function into FPGA chip of DCS system module of the present invention;

[0051] Figure 2 It is a flow chart of the present invention for introducing the ECC check function into the FPGA chip of the DCS system module;

[0052] In the figure, 1 is a maintenance computer, 2 is a communication connection cable, 3 is a DCS system module, 4 is an FPGA chip, 5 is a solid-state memory, and 6 is a flash memory. DETAILED DESCRIPTION

[0053] The present invention will be further described below in conjunction with the accompanying drawings.

[0054] The modules containing FPGA chips in the DCS system of power station generator sets mainly include communication modules (such as modules that realize tracking and switching functions between redundant CPU control units), I / O input and output modules, etc.

[0055] Data errors caused by high-energy neutron radiation are physical phenomena that cannot be completely eliminated. Generally, when designing chip architecture in the factory, overall reinforcement, introduction of external high-reliability monitoring technology solutions, chip redundancy and other methods are adopted to improve radiation resistance.

[0056] For systems that have already been put into operation, if the system reliability is reduced due to radiation, affecting the safe operation of the generator set, if all modules containing FPGA chips in the entire DCS system are replaced, it will not only be very expensive, but also time-consuming, which will seriously affect the timely commissioning of the unit for power generation.

[0057] Therefore, it is necessary to adopt corresponding technical solutions and measures that are feasible, low-cost, short-implementation time and effective, so as to reduce the module failure rate caused by radiation and improve the reliability of the generator set.

[0058] According to statistics, when FPGA is affected by radiation such as high-energy neutrons, the soft errors generated in its data generally lead to single-bit data errors, and occasionally lead to two or more bit data errors. The probability of the former occurring is about 90%, and the probability of the latter occurring is about 10%. It can be seen that if measures are taken to eliminate the problem of module failure caused by single-bit data errors, the probability of module failure caused by high-energy neutron radiation can be reduced by 90%.

[0059] The technical solution of the present application is mainly aimed at the above-mentioned single-bit data error, and adds ECC error checking and correction checking function to the DCS system module, replacing the original CRC cyclic redundancy check that can only detect errors but cannot automatically correct errors, and realizing the automatic error correction function. In this way, the single-bit data error caused by radiation (the probability of occurrence is about 90%) is automatically corrected during detection, will not affect the module function, and can automatically reset the module; for the problem of module failure caused by two or more bit data errors (the probability of occurrence is about 10%), since the output signal of the failed I / O input and output module will change, there is a risk, so the signal combing and function analysis of the I / O input and output module are carried out. If a single I / O input and output module failure may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules, thereby effectively reducing the adverse effects of a single module failure on the safe operation of the unit.

[0060] Take the coal-fired generator set of a self-provided power plant of a steel enterprise as an example. This unit is a self-provided power plant generator set of the steel enterprise, with a designed installed capacity of 350MW. The DCS system is used to monitor the boiler, turbine, generator and various environmental protection, public auxiliary equipment and other major equipment of the generator set. The hardware of the DCS system is mainly composed of a CPU control unit, various modules and network equipment. The modules mainly include DCS system internal communication modules and I / O input and output modules. Most modules of the DCS system of the generator set contain FPGA chips. The FPGA in the module is mainly used to configure static logic, and its internal data will not be dynamically refreshed. Therefore, the CRC cyclic redundancy check method is used for self-checking to detect unexpected data changes.

[0061] The total number of modules containing FPGA chips in the DCS system of this generator set is about 1,500. According to probability calculations, the average number of module failures caused by high-energy neutron radiation is about 12 to 20 times per year, which poses a great risk to the safe operation of the DCS system and the generator set. Taking May 2018 to May 2019 as an example, the DCS system of this unit experienced similar anomalies 14 times in one year. According to the module fault log information records, the CRC cyclic redundancy check detected that the FPGA chip data in the module was wrong, but because the CRC cyclic redundancy check could not automatically correct the error, the module function failed and an alarm was triggered after the data error.

[0062] The internal communication module of the DCS system of the unit is redundantly configured. When a module fails, it can automatically switch to the online standby module without causing system disturbance. However, the module needs to be manually "reset" (also known as "resetting" or "restarting", which refers to the "power off" and "power on" operations of the corresponding module) before it can return to normal. There is a risk of misoperation when the unit is in operation, which may cause network communication interruption and unit shutdown. The analog output (AO) module and digital output (DO) module in the I / O input and output module will suddenly change the module signal value from the current value to 0 after an abnormality, which may cause the field equipment driven by it to malfunction, posing a great risk to the safe operation of the unit and the equipment. At the same time, the I / O input and output module also needs to be manually reset (usually the "unplug" and "plug" operations of the corresponding module are performed online) before it can return to normal. Since the unit is running, there is a certain risk in manual operation, and the slightest carelessness may cause the unit to reduce load or even shut down.

[0063] This technical solution, that is, to address the above-mentioned problems, combines the module types of the generator set DCS system containing FPGA chips, analyzes and provides solutions, so as to significantly reduce the probability of module failure caused by the influence of high-energy neutron radiation on the FPGA chip of the generator set DCS system module, thereby improving the operating reliability of the DCS system and the generator set.

[0064] Specifically, since the data of semiconductor device integrated circuits may undergo unexpected changes during transmission and storage due to radiation and other reasons, data verification is usually used in existing technical solutions to ensure the integrity and accuracy of the data.

[0065] Traditionally used data verification methods are parity check and CRC cyclic redundancy check, which can detect one or more bit errors but cannot achieve error correction.

[0066] The ECC error checking and correction verification overcomes the defects of these two types of verification, and can realize the functions of automatic error correction of one-bit data and error detection of two-bit data. When the FPGA chip is exposed to radiation and the data is erroneous, if only one bit of the data is erroneous, the ECC error checking and correction verification will automatically correct the error of this bit, so that the module function is not affected and maintains normal operation; if there is an error in two or more bits of data, the ECC error checking and correction verification will notify the CPU control unit that a data error has occurred.

[0067] The core content of this technical solution is:

[0068] 1) For the approximately 1,500 DCS system internal communication modules, I / O input and output modules, etc. that contain FPGA chips in the generator set DCS system, the existing DCS system architecture and hardware that have been put into production are retained. Only the ECC error check and correction check import of the modules containing FPGA chips are performed by taking advantage of the unit shutdown and maintenance opportunity, thereby greatly reducing the module failure rate caused by such abnormalities (reduced by 90%), and realizing the automatic reset function of the module after the abnormality, effectively avoiding the risk of misoperation of online manual reset of the module.

[0069] The introduction of ECC error checking and correction verification functions only involves the firmware storage area of ​​the flash memory (Flash-ROM) in the FPGA chip.

[0070] Flash memory is a non-volatile memory. Its most significant feature is that it can electronically erase / write and reprogram memory cells called blocks. The write operation of any flash memory device can only be performed in empty or erased cells, so in most cases, an erase operation must be performed before a write operation.

[0071] Since the ECC function requires a large amount of data space, for modules with insufficient blank cells in the FPGA chip, the original data in the firmware storage area must first be erased (the data in other storage areas remain unchanged) and then the ECC function is imported.

[0072] 2) For module failures caused by data flipping of two or more bits (the probability of occurrence is about 10%), the ECC check function can detect the failure and alarm, but it cannot automatically correct the error. Therefore, the signal function of the I / O input and output module is analyzed. If the failure of a single I / O input and output module may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules, thereby effectively reducing the adverse effects of a single module failure on the safe operation of the unit.

[0073] The specific implementation steps of this technical solution are as follows:

[0074] 1. The generator set and DCS system stop running:

[0075] Since the DCS system communication module must be unplugged, the CPU control unit must be disabled, and the I / O input and output modules must be powered off during the generator set shutdown process when the ECC error checking and correction verification function is introduced into each module of the generator set DCS system, it must be implemented during the generator set shutdown period, and all field equipment controlled by the DCS system must be disabled or switched to local control before the DCS system is disabled.

[0076] 2. Import ECC error checking and correction function into the communication module:

[0077] The DCS system has a small number of communication modules, about 50. When introducing the ECC error checking and correction verification function, a maintenance card slot is used. The communication modules are unplugged one by one and inserted into the maintenance card slot.

[0078] The hardware modules involved in this step and their connections are as follows: Figure 1 as shown in .

[0079] Since the maintenance computer and maintenance card slot are standard maintenance tools that are provided by the manufacturer of the DCS system computer of the generator set, and for industrial computer systems, the corresponding maintenance computer and maintenance card slot provided by the manufacturer are already standard configurations, the specific working principle, specific connection relationship and use method of the maintenance computer and maintenance card slot of the DCS system computer will not be described here. Those skilled in the art can complete the relevant connection and normal use of the corresponding maintenance computer and maintenance card slot according to the technical information, maintenance manual or random technical information provided by the DCS system manufacturer.

[0080] Specific steps for introducing ECC error checking and correction function into the communication module:

[0081] (1) Unplug each communication module from the DCS system and insert it into the maintenance card slot equipped with power supply. Connect the maintenance computer and the communication module with the communication cable;

[0082] (2) Using the software tool of the maintenance computer and the read-back function, read all the data in the flash memory (Flash-ROM) of the FPGA chip in the communication module and store it in the computer;

[0083] (3) The introduction of ECC error checking and correction verification functions only involves the firmware storage area of ​​the flash memory in the FPGA chip, so the original data in the firmware storage area is erased (the data in other storage areas remains unchanged);

[0084] (4) Importing new data (ECC error checking and correction function) into the firmware storage area of ​​the flash memory in the FPGA chip;

[0085] (5) All data in the flash memory of the FPGA chip into which the new data has been imported are read back to the maintenance computer and stored;

[0086] (6) Use software tools to compare all the flash memory data read twice to confirm that the data in the firmware storage area is updated correctly and other data in the non-firmware storage area remains unchanged;

[0087] (7) The communication module completes the ECC error checking and correction verification function import.

[0088] The specific operation process of introducing the ECC check function into the FPGA chip of the DCS system module in this technical solution is shown in Figure 2 as shown in .

[0089] 3. Import ECC error checking and correction function to I / O input and output modules:

[0090] There are a lot of I / O input and output modules, about 1450 in total, of 7 types. In the DCS system, 8 I / O input and output modules form a group. The communication function between the CPU control unit and the I / O input and output modules is realized through an I / O communication module. When importing, the modules are taken as a group. The I / O input and output modules do not need to be unplugged during the import process and remain in the DCS system card slot.

[0091] Before importing, the CPU control unit corresponding to this group of modules is disabled, and the communication cable is used to connect the maintenance computer and the I / O communication module corresponding to this group of modules. The software tool in the maintenance computer embeds the I / O input and output module configuration file. After starting the software tool, the configuration file automatically identifies the type and data version of each I / O input and output module, and automatically executes the data import of this group of I / O input and output modules in sequence.

[0092] Specific steps for introducing ECC error checking and correction function to I / O input and output modules:

[0093] (1) The DCS system CPU control unit corresponding to the I / O input and output module group is disabled;

[0094] (2) Communication cable connects the maintenance computer and the I / O communication module;

[0095] (3) Importing software tools and I / O module input and output configuration files into the I / O communication module;

[0096] (4) The I / O input and output module is powered off and then powered on again (i.e. the module is restarted);

[0097] (5) Start the software tool and import the data of the group of I / O input and output modules in sequence (block 1 to block 8);

[0098] (6) The software tool automatically identifies the type and data version of the first I / O input / output module, and uses the read-back function to read and store all the data in the flash memory (Flash-ROM) of the FPGA chip in the first I / O input / output module;

[0099] (7) The introduction of ECC error checking and correction verification functions only involves the firmware storage area of ​​the flash memory in the FPGA chip, so the original data in the firmware storage area is erased (the data in other storage areas remains unchanged);

[0100] (8) Importing new data (ECC error checking and correction function) into the firmware storage area of ​​the flash memory in the FPGA chip;

[0101] (9) Read back and store all the data in the flash memory of the FPGA chip into which the new data has been imported;

[0102] (10) The software tool compares all the flash memory data read twice to confirm that the data in the firmware storage area is updated correctly and other data in the non-firmware storage area remains unchanged;

[0103] (11) The first I / O input / output module of the group completes the ECC error checking and correction check function introduction;

[0104] (12) The software tool repeats steps (6) to (11) above to complete the introduction of the ECC error checking and correction check function for the 2nd to 8th I / O input and output modules of the group;

[0105] (13) Repeat the above steps (1) to (12) to complete the introduction of ECC error checking and correction check functions for all groups of I / O input and output modules.

[0106] 4. For signals arranged on the same I / O input / output module, analyze the function of each signal. If the failure of a single I / O input / output module may cause abnormal shutdown of important equipment or units, reallocate the signals on the module to other modules, thereby effectively reducing the adverse effects of a single module failure on the safe operation of the unit.

[0107] Since all the data of the flash memory (Flash-ROM) of the FPGA chip in the communication module is read and stored in an external maintenance computer, or, a software tool (usually capable of performing related operations of reading, writing and verifying the contents of the flash memory, for example, the technical solution disclosed in Chinese invention patent CN201310298245.2 "Method for reading data in a block in a flash memory and related memory device") is used, all the data of the flash memory of the FPGA chip is read and stored in an external maintenance computer, and the new data is re-imported into the firmware storage area of ​​the flash memory in the FPGA chip to update the data in the flash memory firmware storage area, which belongs to the existing technical solution (for example, by updating the ROM storage area data of the computer motherboard control chip to upgrade the motherboard control program, which is the same technical solution means), the specific operation steps or principles of reading, updating, verifying and writing back the ROM storage area data in the above steps will not be described here. After mastering the idea of ​​solving the problem of this technical solution, technical solution personnel in this field will have no difficulty in using corresponding software with ROM storage area data reading, verification and data writing back functions, and completing the operating steps of the corresponding data reading, verification and data writing back functions according to the software instructions or help file.

[0108] Through the implementation and application of this technical solution, the following objectives are achieved:

[0109] First, for the generator sets and DCS systems that have been put into operation, if they are affected by radiation and the system reliability decreases, affecting the safe operation of the generator sets, if all the modules containing FPGA chips in the entire DCS system are replaced, it will not only be very expensive, but also time-consuming, which will seriously affect the timely commissioning of the units for power generation.

[0110] The adoption of this technical solution does not involve changes to the architecture and hardware of the existing DCS system. It has high feasibility, low implementation cost, short implementation time and obvious effects.

[0111] Secondly, when the technical solution is implemented, it only takes the opportunity of the unit being shut down for maintenance, which can be completed in a short time without affecting the normal operation and power generation of the unit, thus avoiding power generation losses.

[0112] Third, after the implementation of this technical solution, the probability of module failure is greatly reduced. As mentioned above, the incidence of module failure caused by this type of abnormality is reduced by 90%; and various modules can automatically reset without disturbance after such abnormality occurs, and quickly restore normal functions without manual reset, greatly reducing the risk of manual misoperation. And by analyzing the signal function of the I / O input and output module, for a single I / O input and output module failure that may cause abnormal shutdown of important equipment or units, the signals on the module are redistributed to other modules, effectively reducing the adverse effects of a single module failure on the safe operation of the unit.

[0113] During the one-year period after the implementation of this technical solution in the DCS system of the generator set of a self-contained power plant of a steel enterprise, this type of module failure occurred only twice, a significant decrease in frequency year-on-year, and the module quickly and automatically restored normal function after the failure, achieving the expected technical solution effect.

[0114] The technical solution of the present invention implements an automatic error correction function by performing ECC error checking and correction check import on a module containing an FPGA chip in a DCS system of a generator set, thereby reducing the probability of module failure caused by the FPGA chip of the DCS system module of the generator set being affected by high-energy neutron radiation, thereby improving the operating reliability of the DCS system and the generator set.

[0115] The invention can be widely used in the field of operation, maintenance or reconstruction of a DCS system of a power station generator set.

Claims

1. A method for improving the reliability of a DCS system module of a power station generator set, characterized by: The first step is to keep the existing DCS system architecture and hardware that have been put into production and use unchanged for the DCS system internal communication modules and I / O input and output modules that contain FPGA chips in the DCS system of the generator set. Only when the unit is shut down for maintenance, ECC error check and correction verification are carried out on the modules containing FPGA chips to realize automatic error correction function. The second step is to analyze the signal functions of the I / O input / output modules. If a single I / O input / output module failure may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules to effectively reduce the adverse effects of a single module failure on the safe operation of the unit. Among them, the ECC error check and correction check import is performed on the module containing the FPGA chip, at least including the import of the ECC error check and correction check function on the communication module and the import of the ECC error check and correction check function on the I / O input and output module; The method of introducing the ECC error checking and correction check function to the I / O input / output module comprises at least the following steps: (1) The DCS system CPU control unit corresponding to the I / O input and output module group is disabled; (2) Communication cable connects the maintenance computer and the I / O communication module; (3) Importing software tools and I / O module input and output configuration files into the I / O communication module; (4) The I / O input and output module is powered off and then powered on again to restart the module; (5) Importing data of the group of I / O input and output modules in sequence; (6) Automatically identify the type and data version of the first I / O input / output module, and use the read-back function to read and store all the data in the flash memory of the FPGA chip in the first module I / O input / output module; (7) Erase the original data in the firmware storage area of ​​the flash memory in the FPGA chip, and keep the data in other storage areas unchanged; (8) Importing the data of the ECC error checking and correction function into the firmware storage area of ​​the flash memory in the FPGA chip; (9) Read back and store all the data in the flash memory of the FPGA chip into which the new data has been imported; (10) Compare all the flash memory data read twice to confirm that the data in the firmware storage area is updated correctly and other data in the non-firmware storage area remains unchanged; (11) The first I / O input / output module of the group completes the ECC error checking and correction check function introduction; (12) The software tool repeats steps (6) to (11) above to complete the introduction of the ECC error checking and correction check function for the 2nd to 8th I / O input and output modules of the group; (13) Repeat the above steps (1) to (12) to complete the introduction of ECC error checking and correction check functions for all groups of I / O input and output modules; The method for improving the reliability of the DCS system module of the power station generator set reduces the probability of module failure caused by the FPGA chip of the DCS system module of the generator set being affected by high-energy neutron radiation through the above steps, thereby improving the operating reliability of the DCS system and the generator set.

2. The method for improving the reliability of the DCS system module of a power station generator set according to claim 1, characterized in that The ECC error check and correction verification import of the module including the FPGA chip includes erasing the original data in the firmware storage area of ​​the flash memory in the FPGA chip, maintaining the data in other storage areas unchanged, and then importing the ECC function to realize the update of the data in the flash memory firmware storage area.

3. The method for improving the reliability of the DCS system module of the power station generator set according to claim 1, characterized in that The method for improving the reliability of the DCS system module of the power station generator set adds an ECC error checking and correction check function to the DCS system module for single-bit data errors, replacing the original CRC cyclic redundancy check that can only detect errors but cannot automatically correct errors, thereby realizing an automatic error correction function.

4. The method for improving the reliability of the DCS system module of a power station generator set according to claim 1, characterized in that The method for improving the reliability of the DCS system module of the power station generator set is to sort out the signals and analyze the functions of the I / O input and output modules for the problem of module failure caused by two or more bit data errors. If the failure of a single I / O input and output module may cause abnormal shutdown of important equipment or units, the signals on the module are reallocated to other modules, thereby effectively reducing the adverse effects of the failure of a single module on the safe operation of the unit.

5. The method for improving the reliability of the DCS system module of a power station generator set according to claim 3 or 4 is characterized in that for the module containing the FPGA chip, if only one bit of the data has an error, the ECC error check and correction check automatically corrects the error of this bit, so that the function of the module is not affected and maintains normal operation; if two or more bits of data have an error, the ECC error check and correction check will notify the CPU control unit that a data error has occurred.

6. The method for improving the reliability of the DCS system module of a power station generator set according to claim 1, characterized in that The introduction of ECC error checking and correction checking function into the communication module at least comprises the following steps: (1) Unplug each communication module from the DCS system and insert it into the maintenance card slot equipped with power supply. Connect the maintenance computer and the communication module with the communication cable; (2) Using the software tool on the maintenance computer and the read-back function, read all the data from the flash memory of the FPGA chip in the communication module and store it in the computer; (3) Erase the original data in the firmware storage area of ​​the flash memory in the FPGA chip, and keep the data in other storage areas unchanged; (4) Importing the data of the ECC error checking and correction function into the firmware storage area of ​​the flash memory in the FPGA chip; (5) All data in the flash memory of the FPGA chip into which the new data has been imported are read back to the maintenance computer and stored; (6) Compare all the flash memory data read twice to confirm that the data in the firmware storage area is updated correctly and other data in the non-firmware storage area remains unchanged; (7) The communication module completes the ECC error checking and correction verification function import.

7. The method for improving the reliability of the DCS system module of a power station generator set according to claim 1, characterized in that The method for improving the reliability of the DCS system module of the power station generator set is to effectively reduce the probability of module failure caused by the FPGA chip in the DCS system module of the power station generator set being affected by radiation, improve the reliability of the DCS system module of the power station generator set, and ensure the safe and stable operation of the DCS system and the generator set by introducing the ECC error check and correction check function into the module containing the FPGA chip in the DCS system.

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