Gas turbine control system of double-controller parallel collaborative architecture and verification method

Abstract

The invention discloses a gas turbine control system of a double-controller parallel collaborative architecture and a verification method. The gas turbine control system is characterized in that a programmable controller is introduced into the system to serve as auxiliary control equipment; the original controller of the gas turbine is still responsible for realizing the starting, sequential control, main control and protection control functions of the gas turbine, and the programmable controller which is in parallel cooperative control with the original controller of the gas turbine supports the input of a third-party control algorithm. The instruction decision module is used for judging a rotating speed controller calculation instruction signal actually input into the gas turbine; the minimum value selector is used for screening a fuel flow signal actually input into the gas turbine; the gas turbine body simulation model and the data analysis module are both used for judging operation performance changes of the gas turbine, and online parameter adjustment of a third-party control algorithm in the programmable controller is achieved. The data acquisition module is mainly used for acquiring state parameter signals of the gas turbine. According to the method, the problems of high full-physical test risk and difficulty in implementation in the current gas turbine control algorithm development process are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of gas turbines, and in particular relates to a gas turbine control system and a verification method with a dual-controller parallel collaborative architecture. Background Art

[0002] The safe and stable operation of gas turbines is inseparable from a control system with excellent performance. In the process of developing the control system of gas turbines, it is necessary to test and verify various operating conditions of gas turbines to verify the reliability and stability of the control system. Gas turbines are a kind of power equipment with complex operating conditions, extreme internal working environment and high nonlinearity. The verification test of its control system has practical problems such as high risk and high trial and error cost. Due to the practical problems of gas turbine actual machine testing, the development of control algorithms in the field of gas turbines is mostly limited to simulation testing and semi-physical simulation verification stages. There is no test platform in China that uses a fully physical method to carry out control algorithm test verification. However, only through simulation testing or semi-physical simulation verification, it is impossible to accurately simulate the influence of many uncertain factors such as measurement noise and external operating environment on the control algorithm during the actual operation of the gas turbine. Full physical test verification is the most effective way to test the true effect of the control algorithm. Summary of the invention

[0003] In order to solve the above technical problems, the present invention proposes a gas turbine control system and verification method with a dual-controller parallel collaborative architecture, which supports the verification of the control algorithm developed based on MATLAB / Simulink software in the test unit and ensures the safety of the gas turbine during the test process, thereby realizing the rapid prototyping design of the control algorithm.

[0004] On the one hand, to achieve the above-mentioned object, the present invention provides a gas turbine control system with a dual-controller parallel collaborative architecture, comprising:

[0005] Programmable controller, gas turbine speed main controller, gas turbine limit protection control logic, instruction decision module, minimum value selector, gas turbine actual unit, data acquisition module, gas turbine mechanism simulation model, data analysis module;

[0006] The programmable controller is used to run a third-party control algorithm and verify the validity of the written control algorithm;

[0007] The main gas turbine speed controller is the original controller of the gas turbine test unit, which is used to realize the speed control of the basic startup, load increase and decrease, and shutdown process of the gas turbine;

[0008] The gas turbine limit protection control logic is a protection program of the original control system of the gas turbine, which is used to protect the gas turbine from running in a safe operation area;

[0009] The command decision module is used to realize the switching between the control commands calculated by the gas turbine speed main controller and the programmable controller, and realize the disturbance-free switching between the traditional control algorithm and the developed third-party control algorithm;

[0010] The minimum value selector is used to determine the actual output value of the protection control logic and the speed main controller operation instruction;

[0011] The gas turbine actual unit is used to receive control command input from the control system and send sensor measurement signals to the control system;

[0012] The data acquisition module is used to measure the actual operating temperature, pressure and speed status signals of the gas turbine through sensors and send them to the gas turbine control system;

[0013] The gas turbine mechanism model is used to calculate the simulation value of the gas turbine output state parameter by receiving the fuel flow command of the gas turbine control system, and judge whether the gas turbine has performance degradation and failure by comparing the state parameter simulation value with the sensor measured value, so as to adjust the controller parameters and realize the safe, efficient and stable operation of the gas turbine;

[0014] The data analysis module is used to compare the sensor measurement parameters of the gas turbine with the simulation parameters of the simulation model to achieve online parameter adjustment of the control algorithm.

[0015] On the other hand, to achieve the above-mentioned purpose, the present invention provides a full physical test verification method for a gas turbine control system, comprising:

[0016] According to the design objectives and plans of the gas turbine control system, formulate the test outline and test plan, and clarify the test conditions and implementation steps of the gas turbine;

[0017] The control algorithm to be tested is downloaded to the programmable controller. The original main controller of the gas turbine still uses the traditional PID speed control algorithm;

[0018] Start the gas turbine according to the startup procedure in the original control system of the gas turbine and operate the gas turbine stably under the set working conditions;

[0019] Determine whether the parameters of the engine and controller are normal, and whether it is necessary to switch control rights;

[0020] The actual gas turbine unit and the gas turbine simulation model simultaneously receive the input command signal output by the controller, and output the measured value and simulated value of the gas turbine state parameters respectively; the data analysis module determines the health status of the unit by comparing the measured value and simulated value of the gas turbine state parameters, and adjusts the control parameters of the advanced control algorithm in the programmable controller; after all test conditions are completed, the control right is switched from the programmable controller to the original speed controller of the gas turbine; finally, the control system completes the shutdown process of the gas turbine according to the prescribed process.

[0021] Optionally, the method for determining whether the control right needs to be switched includes:

[0022] Whether to switch the speed controller is determined according to the operating status of the gas turbine. If the gas turbine is in a stable state, the main speed controller is switched from the original speed controller of the gas turbine to the programmable controller, and the control function of the gas turbine is realized by the developed control algorithm. If the operating status of the gas turbine is still unstable, the gas turbine continues to be controlled by the original speed controller of the gas turbine until the operating status of the gas turbine is stable and the controller is switched.

[0023] Technical effect of the invention: The present invention discloses a gas turbine control system and verification method with a dual-controller parallel collaborative architecture, which realizes the parallel collaborative control of the dual controllers on the original control system of the gas turbine by means of parallel programmable controllers, completes the full physical verification function of the control algorithm, minimizes the changes to the gas turbine control system, still retains the basic architecture of the original control system, and reduces the risks brought by the transformation of the control system. At the same time, many limit protection control logics such as speed limit protection, surge limit protection and temperature limit protection are set to reduce the safety risks in the control algorithm testing process. The verification platform can realize rapid prototype verification of a variety of advanced control algorithms, meet the testing requirements of the algorithms under different working conditions, greatly shorten the process from research and development to engineering application of the control algorithm, reduce the research and development time, reduce the verification risk, and is more conducive to the engineering application of advanced control algorithms. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings constituting a part of the present application are used to provide a further understanding of the present application. The illustrative embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0025] Figure 1 A schematic diagram of the structure of a gas turbine control system with a dual-controller parallel collaborative architecture according to an embodiment of the present invention;

[0026] Figure 2 This is a hardware architecture diagram of a gas turbine control system according to an embodiment of the present invention;

[0027] Figure 3The present invention is a flowchart of a gas turbine control method with a dual-controller parallel collaborative architecture according to an embodiment of the present invention. DETAILED DESCRIPTION

[0028] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0029] It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and that, although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0030] like Figure 1 As shown, in this embodiment, a gas turbine control system with a dual-controller parallel collaborative architecture is provided, including: a programmable controller; a main controller of the gas turbine speed; a gas turbine limiting protection control logic, an instruction decision module, a minimum value selector, a gas turbine actual unit, a data acquisition module, a gas turbine mechanism simulation model, and a data analysis module.

[0031] Programmable controller, used to run third-party control algorithms and verify the effectiveness of the written control algorithms.

[0032] The main gas turbine speed controller is the original controller of the gas turbine test unit, which is used to realize the speed control of the basic startup, load increase and decrease, and shutdown process of the gas turbine;

[0033] The gas turbine limit protection control logic is the protection program of the original control system of the gas turbine, which is used to protect the gas turbine from running in the safe operation area;

[0034] The command selection module is used to switch between the control commands calculated by the gas turbine speed main controller and the programmable controller, and to achieve disturbance-free switching between traditional control algorithms and developed third-party control algorithms;

[0035] Minimum value selector, used to decide the actual output value of the protection control logic and the speed main controller operation instruction;

[0036] The actual gas turbine unit includes at least compressor components, combustion chamber components, turbine components and auxiliary equipment, which are used to receive control command input from the control system and send sensor measurement signals to the control system;

[0037] The data acquisition module is used to measure the actual operating temperature, pressure and speed status signals of the gas turbine through sensors and send them to the gas turbine control system;

[0038] The gas turbine mechanism model at least includes accurate models of the compressor, combustion chamber, and turbine core components. The gas turbine mechanism model receives the fuel flow command from the gas turbine control system, calculates the simulation value of the gas turbine output state parameter, and judges whether the gas turbine has performance degradation and failure by comparing the simulated value of the state parameter with the actual measured value of the sensor, thereby adjusting the controller parameters to achieve safe, efficient and stable operation of the gas turbine.

[0039] The data analysis module is used to compare the sensor measurement parameters of the gas turbine with the simulation model simulation parameters to achieve online parameter adjustment of the control algorithm.

[0040] During the verification test of the control system, the state parameter signals measured by the sensor are respectively transmitted to the limit protection control logic, the speed main control logic and the advanced control algorithm in the programmable controller. The instruction selection module is essentially a selector, which selects the control instructions actually output by the speed main control logic and the advanced control algorithm according to the switching instructions input from the outside. Finally, the fuel flow control instructions calculated by all sub-control modules are filtered out by the maximum and minimum value selectors in the original controller of the gas turbine to obtain the actual fuel flow instructions. Finally, the fuel flow instruction output controls the fuel actuator to change the fuel flow output value, thereby achieving the purpose of controlling the stable operation of the gas turbine generator set.

[0041] The gas turbine mechanism simulation model at least includes Simulink simulation models of core components such as compressor, turbine, combustion chamber, and shaft. The gas turbine mechanism simulation model calculates the simulation value of the gas turbine state parameter according to the fuel flow command output by the controller. The data analysis module determines the performance change of the gas turbine by calculating the relative error between the measured value and the simulation value of the gas turbine state parameter. Then, the data analysis module feeds back the performance change of the gas turbine to the programmable controller. The advanced control algorithm installed in the programmable controller adjusts the gain parameter of the control algorithm according to the performance degradation of the gas turbine, so as to realize the adaptive tracking of the performance state of the gas turbine by the control algorithm.

[0042] Figure 2 The hardware architecture diagram of the gas turbine control system is shown in Figure 1. The hardware equipment of the verification platform includes: the original controller host computer of the gas turbine, the programmable controller host computer, the commercial TC100 controller of the gas turbine, the programmable controller, the fuel actuator and the gas turbine generator set. The gas turbine generator set shown in the figure is a 100kW single-shaft micro gas turbine.

[0043] The host computer of the original gas turbine controller is used to monitor the gas turbine status parameters, send control instructions, and compile control system programs.

[0044] The programmable controller host computer is used for programming advanced control algorithms and high-precision mechanism models of gas turbines, as well as downloading and compiling them to the programmable controller. It also has the function of online adjustment of control algorithm parameters. The programmable controller host computer uses a commercial computer and is installed with software such as MATLAB / Simulink, Labview / Veristand, etc. The control algorithm and gas turbine program are usually developed based on the MATLAB / Simulink platform. The Simulink Coder, Simulink Real-Time, and Embedded Coder functions in Matlab software are used to compile the graphical model into binary code that can run on the model simulator and controller (DSP / PLC), realizing the rapid development of gas turbine control systems.

[0045] The commercial TC100 controller for gas turbines is the controller hardware configured by the manufacturer when the gas turbine generator set leaves the factory. It is equipped with the original control system of the gas turbine, including the main speed controller, the limiting protection controller, and the data acquisition and processing module. It is used to achieve the set control objectives, monitor the performance parameters of the gas turbine, and ensure the safe operation of the gas turbine. It is worth noting that this verification platform does not change the control logic in the commercial TC100 controller for gas turbines, and realizes the established functions through the parallel collaborative control of dual controllers.

[0046] Programmable controller, used to run the developed advanced control algorithm. The programmable controller is in parallel with the commercial TC100 controller for gas turbines. The programmable controller receives the measured values ​​of the gas turbine state parameters processed by the gas turbine TC100 controller. The control algorithm inside the programmable controller calculates the fuel flow command signal based on the measured values ​​of the gas turbine state parameters and transmits it to the TC100 controller. The TC100 controller determines the fuel flow command that is ultimately transmitted to the fuel actuator by comparing the control command of the programmable controller with the limit protection control command. The programmable controller and the TC100 controller are connected via TCP / IP communication.

[0047] Connection and communication methods of hardware equipment components:

[0048] The commercial TC100 controller for gas turbines is connected to the sensor components of the gas turbine generator set to obtain key performance parameters such as the speed, temperature, pressure and vibration of the gas turbine; the host computer of the original controller of the gas turbine is connected to the commercial TC100 controller of the gas turbine through a network cable, and the host computer of the original controller obtains the operating status parameters of the gas turbine from the TC100 controller and downloads the compiled control system code to the TC100 controller to realize the parameter adjustment of the control system; the host computer of the programmable controller is connected to the programmable controller through a network cable, and the host computer of the programmable controller uses the internal MATLAB / Simulink, Labview / Veristand and other software to complete the code writing and compilation of advanced control algorithms, and the compiled control algorithm code is downloaded to the programmable controller through the network cable. During the operation of the programmable controller, on the one hand, the programmable controller transmits the key control performance parameters of the gas turbine to the upper computer through the network cable in real time, so as to complete the online monitoring of the control performance through the controller upper computer. On the other hand, the upper computer can change the gain parameters of the internal control algorithm of the programmable controller through the network cable in real time to realize the online parameter adjustment function of the control algorithm. The TC100 controller and the programmable controller also realize the signal transmission function through the network cable. The measured values ​​of the state parameters of the gas turbine are transmitted from the TC100 controller to the programmable controller through the network cable. The advanced control algorithm inside the programmable controller calculates the corresponding fuel flow control instructions according to the measured values ​​of the state parameters of the gas turbine. Finally, the fuel flow instructions output by the programmable controller are transmitted to the TC100 controller through the network cable. The TC100 controller judges the fuel flow calculated by the internal control system of the TC100 controller and the fuel flow transmitted by the programmable controller, and finally transmits the actual fuel flow instruction to the fuel actuator, and the fuel actuator outputs the actual fuel to the combustion chamber of the gas turbine. At this point, the control process of the entire gas turbine is completed.

[0049] Figure 3 The following is a flow chart of the gas turbine control algorithm implementation with dual controller parallel collaborative architecture. Figure 3 As shown, the implementation steps of this embodiment are as follows:

[0050] Step 1: According to the design objectives and plans of the gas turbine control system, formulate the test outline and test plan, and clarify the test conditions and implementation plan of the gas turbine;

[0051] Step 2: Download the control algorithm to be tested to the programmable controller. The original main controller of the gas turbine still uses the traditional PID speed control algorithm;

[0052] Step 3: Start the gas turbine according to the startup procedure in the original control system of the gas turbine and operate the gas turbine stably under no-load conditions;

[0053] Step 4: The commercial TC100 controller of the gas turbine obtains the status parameters of the gas turbine in real time;

[0054] Step 5: Check whether the engine state parameters are stable and whether the control right needs to be switched. If yes, proceed to the next step; if no, return to step 4;

[0055] Step 6: The command selection module receives the switching command, the programmable controller is put into operation, and the control amount is calculated according to the real-time data of the gas turbine;

[0056] Step 7: The programmable controller outputs the control command to the commercial TC100 controller of the gas turbine, and finally transmits it to the actuator to control the gas turbine;

[0057] Step 8: Determine whether the test plan is completed. If it is completed, proceed to the next step. If it is not completed, return to step 6 and continue to control the gas turbine operation by the programmable controller.

[0058] Step 9: The command decision module receives the switching command and switches the control right from the programmable controller to the commercial TC100 controller of the gas turbine. The commercial TC100 controller of the gas turbine is put into operation to perform the gas turbine control operation;

[0059] Step 10: Complete the shutdown operation of the gas turbine in sequence;

[0060] The present invention realizes the full physical verification function of the control algorithm by means of the parallel collaborative control of dual controllers on the original control system of the gas turbine, which minimizes the changes to the gas turbine control system, still retains the basic architecture of the original control system, and reduces the risks brought by the transformation of the control system. At the same time, many limiting protection control logics such as speed limit protection, surge limit protection and temperature limit protection are set to reduce the safety risks in the control algorithm testing process. The present invention can realize the rapid prototype verification of various advanced control algorithms, meet the testing requirements of the algorithms under different working conditions, greatly shorten the process from research and development to engineering application of the control algorithm, reduce the research and development time, reduce the verification risk, and is more conducive to the engineering application of advanced control algorithms.

[0061] The above are only preferred specific implementations of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A gas turbine control system with a dual-controller parallel collaborative architecture, characterized in that: include: Programmable controller, gas turbine speed main controller, gas turbine limit protection control logic, instruction decision module, minimum value selector, gas turbine actual unit, data acquisition module, gas turbine mechanism simulation model, data analysis module; The programmable controller is used to run a third-party control algorithm and verify the validity of the written control algorithm; The main gas turbine speed controller is the original controller of the gas turbine test unit, which is used to realize the speed control of the basic startup, load increase and decrease, and shutdown process of the gas turbine; The gas turbine limit protection control logic is a protection program of the original control system of the gas turbine, which is used to protect the gas turbine from running in a safe operation area; The command decision module is used to realize the switching between the control commands calculated by the gas turbine speed main controller and the programmable controller, and realize the disturbance-free switching between the traditional control algorithm and the developed third-party control algorithm; The minimum value selector is used to determine the actual output value of the protection control logic and the speed main controller operation instruction; The gas turbine actual unit is used to receive control command input from the control system and send sensor measurement signals to the control system; The data acquisition module is used to measure the actual operating temperature, pressure and speed status signals of the gas turbine through sensors and send them to the gas turbine control system; The gas turbine mechanism model is used to calculate the simulation value of the gas turbine output state parameter by receiving the fuel flow command of the gas turbine control system, and judge whether the gas turbine has performance degradation and failure by comparing the state parameter simulation value with the sensor measured value, so as to adjust the controller parameters and realize the safe, efficient and stable operation of the gas turbine; The data analysis module is used to compare the sensor measurement parameters of the gas turbine with the simulation parameters of the simulation model to achieve online parameter adjustment of the control algorithm.

2. A full physical test verification method for a gas turbine control system, characterized in that: include: According to the design objectives and plans of the gas turbine control system, formulate the test outline and test plan, and clarify the test conditions and implementation steps of the gas turbine; The control algorithm to be tested is downloaded to the programmable controller. The original main controller of the gas turbine still uses the traditional PID speed control algorithm; Start the gas turbine according to the startup procedure in the original control system of the gas turbine and operate the gas turbine stably under the set working conditions; Determine whether the parameters of the engine and controller are normal, and whether it is necessary to switch control rights; The actual gas turbine unit and the gas turbine simulation model simultaneously receive the input command signal output by the controller, and output the measured value and simulated value of the gas turbine state parameters respectively; the data analysis module determines the health status of the unit by comparing the measured value and simulated value of the gas turbine state parameters, and adjusts the control parameters of the advanced control algorithm in the programmable controller; after all test conditions are completed, the control right is switched from the programmable controller to the original speed controller of the gas turbine; finally, the control system completes the shutdown process of the gas turbine according to the prescribed process.

3. The gas turbine control system full physical test verification method according to claim 2, characterized in that: Methods for determining whether control needs to be switched include: Whether to switch the speed controller is determined according to the operating status of the gas turbine. If the gas turbine is in a stable state, the main speed controller is switched from the original speed controller of the gas turbine to the programmable controller, and the control function of the gas turbine is realized by the developed control algorithm. If the operating status of the gas turbine is still unstable, the gas turbine continues to be controlled by the original speed controller of the gas turbine until the operating status of the gas turbine is stable and the controller is switched.

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