Metal supervision digital management system of gas turbine unit

Abstract

The invention belongs to the technical field of gas unit metal supervision, and particularly relates to a gas unit metal supervision digital management system. The management system comprises a data acquisition module, a data processing module, a data storage and query module and a data application module. The data application module comprises an equipment ledger module, an intelligent analysis module, an auxiliary decision making module, a supervision report module and a three-dimensional display module. The standard specification data are metal supervision inspection items, equipment types, quantity or proportion, defect conditions, operation characteristics and maintenance level data specified in national and industrial standards. The metal supervision digital management system for the gas turbine unit comprises the data acquisition module, the data processing module, the data storage and query module and the data application module, the metal supervision digital level of the gas turbine unit can be improved, the automation degree can be improved, and high real-time performance is achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of metal supervision of gas generator sets, and in particular relates to a digital management system for metal supervision of gas generator sets. Background Art

[0002] Metal supervision is also called metal technical supervision. Its purpose is to timely understand and grasp the quality status of metal parts of equipment through inspection and diagnosis of monitored parts, to prevent various accidents caused by metal material degradation, functional failure, defect expansion, etc. during unit operation, thereby reducing the number and duration of unplanned shutdowns of units, improving the reliability of equipment safe operation, and extending the service life of equipment.

[0003] The development of informatization and digitalization has brought great changes to various industries. However, most metal supervision work in China still adopts a relatively traditional working mode with a low degree of digitalization. It is urgent to introduce more intelligent, efficient and prepared management methods. This project will make advanced explorations in the field of metal supervision. Most of the metal supervision and management systems of traditional gas units are ledger management of equipment, and the metal supervision and inspection data are entered, counted and analyzed through the ledger, with poor real-time performance. Summary of the invention

[0004] In order to solve the problems existing in the above-mentioned prior art, the present invention provides a gas unit metal supervision digital management system, which can improve the digital level of gas unit metal supervision, improve the degree of automation, and have high real-time performance.

[0005] The specific technical solution adopted by the present invention is:

[0006] A digital management system for metal supervision of gas generator sets, the management system comprising a data acquisition module, a data processing module, a data storage and query module and a data application module;

[0007] The data acquisition module can collect the operation process data of typical components, basic static data, inspection data and equipment test data, as well as pre-stored standard specification data and expert experience data;

[0008] The data processing module includes batch computing and real-time / quasi-real-time computing. Batch computing uses MR and Spark computing frameworks, while real-time / quasi-real-time computing uses flink and SparkStreaming computing frameworks.

[0009] The data storage and query module provides data query capabilities through Kafka, SQL client, and files;

[0010] The data application module includes an equipment ledger module, an intelligent analysis module, a decision support module, a supervision report module and a three-dimensional display module.

[0011] The standard specification data mentioned are the metal supervision and inspection items, equipment categories, quantities or proportions, defect conditions, operating characteristics, and maintenance level data specified in national and industry standards.

[0012] The equipment ledger module is divided into a tree diagram according to the hierarchy of power plant-unit-system-equipment-monitored point, and displays the basic information of the monitored equipment. The ledger can also be associated with the corresponding supervision inspection, replacement records, and defect repair data of each equipment to achieve dynamic and static linkage of ledger information.

[0013] The intelligent analysis module adopts causal link analysis technology to establish the association between existing basic static data and operating process data.

[0014] The auxiliary decision-making module integrates industry standards, supervision guidelines, historical supervision and inspection data, defect conditions, and replacement record information, and automatically generates a supervision and inspection management plan based on a preset template.

[0015] The supervision report module realizes the management, archiving, storage and keyword search functions of various supervision and inspection management reports.

[0016] The three-dimensional display module performs three-dimensional modeling on typical components of the gas unit, uses the monitored points of the equipment as the focus points, uses color blocks to distinguish the focus states, uses the global data of the monitored points as the carrier, and links and displays the basic information of the equipment, historical supervision and inspection conditions, replacement information, and defect repair record data.

[0017] The typical components of the gas unit include pipelines within the unit boiler, boiler heating surfaces, turbine rotors and generator rotors.

[0018] The management system also includes a collection sensor and a mounting base for fixing the collection sensor on a typical component of the gas unit. The collection sensor includes one of an ultrasonic flaw detection sensor, a magnetic particle flaw detector, and a hardness tester sensor.

[0019] The mounting seat comprises a liquid cooling seat, a heat dissipation ring and a circulating pump. The liquid cooling seat is a hollow annular structure, and the inner ring of the liquid cooling seat becomes a mounting cavity for fixing the acquisition sensor. An annular liquid storage ring is sleeved in the inner cavity of the liquid cooling seat, and the gap between the liquid storage ring and the liquid cooling seat forms a cooling cavity with a U-shaped cross-section for the flow of coolant. An adhesive sheet is provided on the bottom surface of the liquid cooling seat adjacent to the cooling cavity. The heat dissipation ring is fixedly arranged on the top of the liquid cooling seat, and a spiral heat dissipation coil is arranged in the heat dissipation ring. The heat dissipation coil is sleeved with heat dissipation fins, and a heat dissipation fan is fixed above the heat dissipation fins. The output end of the heat dissipation coil is connected with the inner cavity of the liquid storage ring, and the liquid storage ring is also connected with the input end of the circulating pump. The output end of the circulating pump is connected with the cooling cavity of the liquid storage ring by means of a pipeline, and the output end of the cooling cavity is connected with the input end of the heat dissipation coil by means of a pipeline.

[0020] The beneficial effects of the present invention are:

[0021] The present invention adopts a digital management system for metal supervision of gas generator sets, which includes a data acquisition module, a data processing module, a data storage and query module, and a data application module. It can improve the digital level of metal supervision of gas generator sets, improve the degree of automation, and have high real-time performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a data architecture diagram of the present invention;

[0023] Figure 2 It is a structural schematic diagram of the mounting base of the present invention;

[0024] Figure 3 A schematic diagram of the mounting base when viewed from above;

[0025] Figure 4 A schematic diagram of the mounting base viewed from above;

[0026] In the attached drawings, 1, liquid cooling seat, 2, heat dissipation ring, 3, circulation pump, 4, installation cavity, 5, liquid storage ring, 6, cooling cavity, 7, adhesive sheet, 8, heat dissipation coil, 9, heat dissipation fins, and 10, heat dissipation fan. DETAILED DESCRIPTION

[0027] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments:

[0028] Specific implementation examples Figure 1 As shown, the present invention is a digital management system for metal supervision of gas generator sets, and the management system includes a data acquisition module, a data processing module, a data storage and query module, and a data application module;

[0029] The data acquisition module can collect the operation process data of typical components, basic static data, inspection data and equipment test data, as well as pre-stored standard specification data and expert experience data;

[0030] The data processing module includes batch computing and real-time / quasi-real-time computing. Batch computing uses MR and Spark computing frameworks, while real-time / quasi-real-time computing uses flink and SparkStreaming computing frameworks.

[0031] The data storage and query module provides data query capabilities through Kafka, SQL client, and files;

[0032] The data application module includes an equipment ledger module, an intelligent analysis module, a decision support module, a supervision report module and a three-dimensional display module.

[0033] By combing through the existing middle platform data assets, the present invention will access the missing parts of the operating process data, basic static data, inspection data and equipment test data of the pipelines, turbine blades and generator guard rings within the scope of the gas unit boiler designed by the present invention according to the standard specifications of the middle platform to serve business applications. It has the storage, calculation and processing capabilities to support unstructured data and massive structured data, and meets the requirements of concurrent access and response time of different types of data analysis applications:

[0034] (1) Batch computing: Distributed computing for large-scale parallel batch processing jobs, mainly computing frameworks such as MR and Spark;

[0035] (2) Real-time / quasi-real-time computing: The platform has the ability to process massive amounts of data in milliseconds or seconds, mainly using computing frameworks such as Flink and Spark Streaming;

[0036] (3) Query technology: Provide data query capabilities through Kafka, SQL client, files, etc.

[0037] (4) Data mining technology: the process of searching for information hidden in massive data through algorithms, mainly using Spark MLlib components;

[0038] (5) Multi-tenant management: Implement multi-tenant management for different components of the data center, including tenant security, resource allocation, data isolation, service level, etc.

[0039] (6) Scalability design: The scalable design of the architecture is achieved by building a large-scale cluster through the servers provided by the business middle platform.

[0040] The data collection service is based on the full amount of data and provides data services in real-time or non-real-time mode to realize asset application, definition, review, release process management and other functions to meet users' customized needs for data extraction;

[0041] The data extracted in this project includes three types of data: real-time data, structured data, and unstructured data. The extraction method supports two methods: system automatic extraction and manual entry. Among them, system automatic extraction supports full data extraction, data incremental extraction, and data batch extraction; real-time extraction, scheduled extraction; one-time extraction, scheduled cycle extraction; and supports data structure synchronization.

[0042] When extracting data, a data verification and error correction mechanism is established to ensure that the extracted data is consistent and complete with the data source. Through data collection, real-time data, structured data, and unstructured data are updated to the clean energy smart supervision platform data warehouse in a timely and accurate manner, and as the enterprise's data assets, they provide unified services for applications.

[0043] The standard specification data mentioned are the metal supervision and inspection items, equipment categories, quantities or proportions, defect conditions, operating characteristics, and maintenance level data specified in national and industry standards.

[0044] The equipment ledger module is divided into a tree diagram according to the hierarchy of power plant-unit-system-equipment-monitored point, and displays the basic information of the monitored equipment. The ledger can also be associated with the corresponding supervision inspection, replacement records, and defect repair data of each equipment to achieve dynamic and static linkage of ledger information.

[0045] (1) Power plant level

[0046] Display the basic information of the power plants under the factory's jurisdiction and the status of metal supervision services, so as to facilitate the subsequent access to the power plant ledger for rapid generation and management.

[0047] (2) Unit level

[0048] Taking the unit as the object, the progress information of unit-level metal supervision and inspection work is displayed, including the basic information of the unit and the historical metal supervision and inspection records of the unit.

[0049] (3) System level

[0050] Displays the information of the metal supervision and monitoring system. The project mainly includes the relevant statistical information of each equipment under the supervision and inspection data system of the four major boiler pipelines, turbine blades, and generator retaining rings, including the inspection records, defects and inspection methods (ultrasonic, magnetic powder, hardness, etc.) of each equipment.

[0051] (4) Equipment level (monitoring point)

[0052] The equipment is numbered in sequence according to the medium flow direction (refer to the manufacturer's naming rules and KKS coding rules), and the monitored points are named one by one to form a library of all monitored points of the four major pipelines (the specific names are determined according to the manufacturer's naming rules). The background account supports synchronous updates when equipment changes.

[0053] Displays the component information, parts information and monitoring information of the equipment. Dynamic information includes the number of fault elimination records, modification and replacement records, inspection records, and abnormal records. All data is collated from the supervision report data to provide support for subsequent supervision intelligent analysis;

[0054] The equipment's previous supervisory inspection data are displayed in the form of a form. The business dimensions are counted according to ultrasound, magnetic powder, hardness, wall thickness, and metallographic structure. The time is counted according to the inspection time. The time dimension covers the unit maintenance information. The form is displayed in reverse chronological order.

[0055] The intelligent analysis module adopts causal link analysis technology to establish the association between existing basic static data and operating process data.

[0056] The four major boiler pipelines, turbine blades, and generator guard rings are inspected. According to different inspection items and different monitoring points, the statistical information of the four major boiler pipelines, turbine blades, and generator guard rings is displayed in the form of bar charts and line charts. The health status of the four major boiler pipelines, turbine blades, and generator guard rings is presented from an overall perspective, and comparative analysis of each monitoring point is achieved.

[0057] The auxiliary decision-making module integrates industry standards, supervision guidelines, historical supervision and inspection data, defect conditions, and replacement record information, and automatically generates a supervision and inspection management plan based on a preset template.

[0058] The system needs to comprehensively match the metal supervision inspection items, equipment categories, quantity or proportion, defect conditions, operating characteristics, maintenance levels and other factors specified in national and industry standards to determine the final metal supervision inspection plan. At the same time, in order to make the metal supervision plan closer to reality. The system combines historical metal supervision inspection data analysis reports, uses the report conclusions to screen out equipment found in poor condition in the previous tests, adds them to the supervision plan, and improves the metal supervision plan. Specifically support the formulation of metal supervision plans through the following steps:

[0059] (1) Source of plan basis: Based on the standard "Technical Supervision Regulations for Metals DL / T438", an informationized rule base is formulated as the basis for the formulation of the metal supervision inspection plan. The bidder shall realize the informatization of the four major pipeline clauses in the standard "Technical Supervision Regulations for Metals DL / T438" according to the requirements of the first phase project.

[0060] (2) Constructing an equipment template library: Based on the equipment inventory data, construct a template library for monitored equipment, match the standard rules of the "Metal Technical Supervision Regulations DL / T438", and screen the monitored equipment that meets the rules.

[0061] (3) Defective items: Based on historical supervision and inspection data, screen historical defective equipment, match rules, and screen monitored equipment.

[0062] (4) Customized new items: The system allows personnel to customize the addition of monitored equipment, special supervision, or items that need to be added during the actual inspection process.

[0063] The staff can input the necessary basic information into the system, such as station, unit, maintenance level, start / end time, custom equipment, etc., and the system will generate a metal supervision plan. At the same time, the system supports the full cycle management of the supervision plan, including the approval of the plan, plan execution, testing, and end.

[0064] The supervision report module realizes the management, archiving, storage and keyword search functions of various supervision and inspection management reports.

[0065] The three-dimensional display module performs three-dimensional modeling on typical components of the gas unit, uses the monitored points of the equipment as the focus points, uses color blocks to distinguish the focus states, uses the global data of the monitored points as the carrier, and links and displays the basic information of the equipment, historical supervision and inspection conditions, replacement information, and defect repair record data.

[0066] The three-dimensional digital model of the four major boiler pipelines, turbine blades, and generator guard rings is built. Taking the equipment as the object, the equipment ledger as the basis, and the three-dimensional digital model as the carrier, a graphic and text information display interface that links the three-dimensional model and metal supervision inspection data is constructed, and basic information such as equipment, components, and welds, as well as metal supervision data, are displayed in three dimensions. The system starts with practical applications and provides more flexible and intuitive visual operations.

[0067] The three-dimensional model focuses on the four major boiler pipes, turbine blades, and generator guard rings to improve the refinement of the equipment model. Other equipment, plant buildings, and other parts of the three-dimensional model related to the four major boiler pipes, turbine blades, and generator guard rings are weakened as backgrounds to achieve a balance between practicality, aesthetics, and economy.

[0068] The typical components of the gas unit include pipelines within the unit boiler, boiler heating surfaces, turbine rotors and generator rotors.

[0069] The management system also includes a collection sensor and a mounting base for fixing the collection sensor on a typical component of the gas unit. The collection sensor includes one of an ultrasonic flaw detection sensor, a magnetic particle flaw detector, and a hardness tester sensor.

[0070] The mounting seat includes a liquid cooling seat 1, a heat dissipation ring 2 and a circulating pump 3. The liquid cooling seat 1 is a hollow annular structure. The inner ring of the liquid cooling seat 1 becomes a mounting cavity 4 for accommodating a collection sensor. The collection sensor is either bonded to the detection surface of a typical component by its own detection surface, or is clamped and pushed against the detection surface by the mounting cavity 4. An annular liquid storage ring 5 is sleeved in the inner cavity of the liquid cooling seat 1. The liquid storage ring 5 is used to store coolant. Since the typical components installed usually have high temperature and vibration, in order to avoid the adhesive sheet 7 of the mounting seat from failing to adhere, powdering or breaking at high temperature, the mounting seat has a water cooling function.

[0071] Furthermore, the gap between the liquid storage ring 5 and the liquid cooling seat 1 forms a cooling cavity 6 with a U-shaped cross section for the flow of the coolant, and an adhesive sheet 7 is provided on the bottom surface of the liquid cooling seat 1 adjacent to the cooling cavity 6 .

[0072] The bottom surface of the liquid cooling seat 1 is cooled by the cooling chamber 6, thereby achieving the cooling of the adhesive sheet 7, avoiding the long-term high temperature causing the adhesive sheet 7 to be powdered and broken, and prolonging the residence time of the acquisition sensor. Figure 2 As shown, the U-shaped cooling cavity 6 is installed in the inner cavity of the liquid cooling seat 1, and cools the bottom surface of the liquid cooling seat 1 while also cooling its inner and outer annular surfaces, so that the data transmission part of the acquisition sensor located on the inner annular side can work at a more suitable temperature, further improving the maintenance interval of the acquisition sensor and reducing costs.

[0073] Furthermore, the heat dissipation ring 2 is fixedly arranged on the top of the liquid cooling seat 1, so as to extend the distance between the heat dissipation ring 2 and the hot surface and enhance the heat dissipation effect. A spiral heat dissipation coil 8 is arranged in the heat dissipation ring 2, and heat dissipation fins 9 are sleeved on the heat dissipation coil 8. The heat dissipation fins 9 are used to increase the heat dissipation area of ​​the heat dissipation coil 8. A heat dissipation fan 10 is fixed above the heat dissipation fins 9, and the heat dissipation effect is improved by means of air supply from the heat dissipation fan 10. The output end of the heat dissipation coil 8 is connected with the inner cavity of the liquid storage ring 5, and the liquid storage ring 5 is also connected to the input end of the circulation pump 3. The output end of the circulation pump 3 is connected with the cooling cavity 6 of the liquid storage ring 5 by means of a pipeline, and the output end of the cooling cavity 6 is connected to the input end of the heat dissipation coil 8 by means of a pipeline.

[0074] The liquid storage ring 5 is arranged in the liquid cooling seat 1, which improves the integration of the equipment and facilitates the flexible installation of the sensor. An insulating layer is arranged between the liquid storage ring 5 and the cooling cavity 6 to prevent the cooled liquid in the inner cavity of the liquid storage ring 5 from being directly heated. The circulation of the coolant ensures that the temperature of the liquid entering the cooling cavity 6 is low.

Claims

1. The digital management system for metal supervision of gas generator sets is characterized by: The management system includes a data acquisition module, a data processing module, a data storage and query module and a data application module; The data acquisition module can collect the operation process data of typical components, basic static data, inspection data and equipment test data, as well as pre-stored standard specification data and expert experience data; The data processing module includes batch computing and real-time / quasi-real-time computing. Batch computing uses MR and Spark computing frameworks, while real-time / quasi-real-time computing uses flink and SparkStreaming computing frameworks. The data storage and query module provides data query capabilities through Kafka, SQL client, and files; The data application module includes an equipment ledger module, an intelligent analysis module, a decision support module, a supervision report module and a three-dimensional display module.

2. The gas generator set metal supervision digital management system according to claim 1 is characterized by: The standard specification data mentioned are the metal supervision and inspection items, equipment categories, quantities or proportions, defect conditions, operating characteristics, and maintenance level data specified in national and industry standards.

3. The digital management system for metal supervision of gas generator sets according to claim 1 is characterized by: The equipment ledger module is divided into a tree diagram according to the hierarchy of power plant-unit-system-equipment-monitored point, and displays the basic information of the monitored equipment. The ledger can also be associated with the corresponding supervision inspection, replacement records, and defect repair data of each equipment to achieve dynamic and static linkage of ledger information.

4. The gas generator set metal supervision digital management system according to claim 1 is characterized by: The intelligent analysis module adopts causal link analysis technology to establish the association between existing basic static data and operating process data.

5. The gas generator set metal monitoring digital management system according to claim 1 is characterized by: The auxiliary decision-making module integrates industry standards, supervision guidelines, historical supervision and inspection data, defect conditions, and replacement record information, and automatically generates a supervision and inspection management plan based on a preset template.

6. The gas generator set metal monitoring digital management system according to claim 1 is characterized by: The supervision report module realizes the management, archiving, storage and keyword search functions of various supervision and inspection management reports.

7. The digital management system for metal supervision of gas generator sets according to claim 1 is characterized by: The three-dimensional display module performs three-dimensional modeling on typical components of the gas unit, uses the monitored points of the equipment as the focus points, uses color blocks to distinguish the focus states, uses the global data of the monitored points as the carrier, and links and displays the basic information of the equipment, historical supervision and inspection conditions, replacement information, and defect repair record data.

8. The digital management system for metal supervision of gas generator sets according to claim 1 or 7, characterized in that: The typical components of the gas unit include pipelines within the boiler range of the unit, boiler heating surfaces, turbine rotors and generator rotors.

9. The digital management system for metal supervision of gas generator sets according to claim 1 is characterized by: The management system also includes a collection sensor and a mounting base for fixing the collection sensor on a typical component of the gas unit. The collection sensor includes one of an ultrasonic flaw detection sensor, a magnetic particle flaw detector, and a hardness tester sensor.

10. The gas generator set metal monitoring digital management system according to claim 1, characterized in that: The mounting seat comprises a liquid cooling seat (1), a heat dissipation ring (2) and a circulation pump (3); the liquid cooling seat (1) is a hollow annular structure; the inner annular portion of the liquid cooling seat (1) forms a mounting cavity (4) for fixing a collection sensor; an annular liquid storage ring (5) is sleeved in the inner cavity of the liquid cooling seat (1); a gap between the liquid storage ring (5) and the liquid cooling seat (1) forms a cooling cavity (6) with a U-shaped cross section for the flow of cooling liquid; an adhesive sheet (7) is provided on the bottom surface of the liquid cooling seat (1) adjacent to the cooling cavity (6); the heat dissipation ring (2) is fixedly arranged on the liquid cooling seat (1) ), a spiral heat dissipation coil (8) is arranged in the heat dissipation ring (2), a heat dissipation fin (9) is sleeved on the heat dissipation coil (8), a heat dissipation fan (10) is fixed above the heat dissipation fin (9), the output end of the heat dissipation coil (8) is connected to the inner cavity of the liquid storage ring (5), the liquid storage ring (5) is also connected to the input end of the circulation pump (3), the output end of the circulation pump (3) is connected to the cooling cavity (6) of the liquid storage ring (5) by means of a pipeline, and the output end of the cooling cavity (6) is connected to the input end of the heat dissipation coil (8) by means of a pipeline.

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