A gas turbine control system with a dual-controller parallel cooperative architecture and its verification method

Abstract

This invention discloses a gas turbine control system and verification method with a dual-controller parallel collaborative architecture, comprising: introducing a programmable logic controller (PLC) as an auxiliary control device into the system. The original gas turbine controller is still responsible for implementing the gas turbine's start-up, sequential control, main control, and protection control functions. The PLC, which operates in parallel and collaboratively with the original gas turbine controller, supports the input of third-party control algorithms. An instruction selection module is used to determine the actual input speed controller calculation instruction signal to the gas turbine; a minimum value selector is used to filter the actual input fuel flow signal to the gas turbine; the gas turbine body simulation model and data analysis module are both used to determine changes in the gas turbine's operating performance and to realize online parameter adjustment of the third-party control algorithm in the PLC. The data acquisition module is mainly used to acquire the gas turbine's state parameter signals. This invention solves the problems of high risk and difficulty in implementation of full-physical testing in the current development of gas turbine control algorithms.

Description

Technical Field

[0001] This invention belongs to the field of gas turbine technology, and particularly relates to a gas turbine control system and verification method with a dual-controller parallel collaborative architecture. Background Art

[0002] The safe and stable operation of a gas turbine relies heavily on a high-performance control system. During the development of a gas turbine control system, it is necessary to conduct tests and verifications under various operating conditions to validate the reliability and stability of the control system. Gas turbines are power devices with complex operating conditions, extreme internal working environments, and high nonlinearity. Verification tests of their control systems face significant challenges, including high risks and high trial-and-error costs. Due to the limitations of real-world gas turbine testing, the development of control algorithms in the gas turbine field is largely confined to simulation testing and semi-physical simulation verification stages. There is currently no domestic testing platform that utilizes a fully physical approach to verify control algorithms. However, simulation testing or semi-physical simulation verification alone cannot accurately simulate the impact of numerous uncertainties such as measurement noise and the external operating environment on the control algorithm during actual gas turbine operation. Full-physical testing verification is the most effective way to test the true performance of the control algorithm. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention proposes a gas turbine control system and verification method with a dual-controller parallel collaborative architecture. This supports the verification of control algorithms developed based on MATLAB / Simulink software in test units and ensures the safety of the gas turbine during testing, enabling rapid prototyping of control algorithms.

[0004] To achieve the above objectives, this invention provides a gas turbine control system with a dual-controller parallel cooperative architecture, comprising:

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

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

[0007] The gas turbine speed main controller is the original controller of the gas turbine test unit, which is used to realize speed control during the start-up, load increase / decrease and shutdown processes of the gas turbine foundation;

[0008] The gas turbine limiting protection control logic is a protection program for the original control system of the gas turbine, used to protect the gas turbine from operating within a safe operating range;

[0009] The instruction selection module is used to switch between the control instructions calculated by the gas turbine speed main controller and the programmable controller, and to achieve seamless switching between traditional control algorithms and developed third-party control algorithms.

[0010] The minimum value selector is used to determine the actual output value of the protection control logic and the speed main controller's operating command.

[0011] The actual gas turbine unit is used to receive control command inputs 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 simulated values ​​of the gas turbine output state parameters by receiving fuel flow commands from the gas turbine control system. By comparing the simulated values ​​of the state parameters with the measured values ​​of the sensors, it is determined whether the gas turbine has experienced performance degradation or malfunctions, thereby adjusting the controller parameters to achieve 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, so as to realize the online parameter adjustment of the control algorithm.

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

[0016] Based on the design goals and scheme of the gas turbine control system, a test outline and test plan were developed, and the test conditions and implementation steps of the gas turbine were clarified.

[0017] The control algorithm to be tested is downloaded to the programmable controller, while 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 gas turbine control system and run the gas turbine stably under the set operating conditions;

[0019] Determine if the parameters of the gas turbine and controller are normal, and determine if it is necessary to switch control.

[0020] The actual gas turbine unit and the gas turbine simulation model simultaneously receive input command signals from the controller and output the measured and simulated values ​​of the gas turbine state parameters, respectively. The data analysis module judges the health status of the unit by comparing the measured and simulated values ​​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 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 procedure.

[0021] Optionally, methods for determining whether a change of control is necessary include:

[0022] The decision to switch the speed controller is based on the operating status of the gas turbine. If the gas turbine is stable, the main speed controller is switched from the original speed controller to a programmable controller, and the developed control algorithm is used to control the gas turbine. If the gas turbine is still unstable, the original speed controller continues to control the gas turbine until the gas turbine is stable, at which point the controller is switched.

[0023] Technical advantages of this invention: This invention discloses a gas turbine control system and verification method with a dual-controller parallel collaborative architecture. It achieves parallel collaborative control of the two controllers by connecting programmable logic controllers in parallel on the existing gas turbine control system, completing the full physical verification of the control algorithm. This minimizes changes to the gas turbine control system, retains the basic architecture of the original control system, and reduces the risks associated with modifying the control system. Simultaneously, it incorporates numerous limiting and protective control logics, such as speed limit protection, surge limit protection, and temperature limit protection, to reduce safety risks during control algorithm testing. This verification platform enables rapid prototype verification of various advanced control algorithms, meeting the testing requirements of algorithms under different operating conditions. It significantly shortens the process from R&D to engineering application of control algorithms, reduces R&D time, minimizes verification risks, and is more conducive to the engineering application of advanced control algorithms. Attached Figure Description

[0024] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

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

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

[0027] Figure 3This is a flowchart illustrating the implementation of a gas turbine control method with a dual-controller parallel collaborative architecture according to an embodiment of the present invention. Detailed Implementation

[0028] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

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

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

[0031] A programmable logic controller (PLC) is used to run third-party control algorithms and verify the effectiveness of the written control algorithms.

[0032] The gas turbine speed main controller is the original controller of the gas turbine test unit, used to realize speed control during the start-up, load increase / decrease and shutdown processes of the gas turbine foundation;

[0033] The gas turbine limitation and protection control logic is a protection program for the original control system of the gas turbine, used to protect the gas turbine from operating within a safe operating range;

[0034] The instruction selection module is used to switch between the control instructions calculated by the gas turbine speed main controller and the programmable controller, and to achieve seamless switching between traditional control algorithms and developed third-party control algorithms.

[0035] The minimum value selector is used to determine the actual output value of the protection control logic and the speed main controller's operating command;

[0036] An actual gas turbine unit includes at least a compressor component, a combustion chamber component, a turbine component, and auxiliary equipment, which are used to receive control command inputs 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 signals of the gas turbine through sensors and send them to the gas turbine control system.

[0038] A gas turbine mechanism model includes accurate models of core components such as the compressor, combustion chamber, and turbine. By receiving fuel flow commands from the gas turbine control system, the gas turbine mechanism model calculates simulated values ​​of the gas turbine output state parameters. By comparing the simulated values ​​of the state parameters with the measured values ​​of the sensors, it determines whether the gas turbine has experienced performance degradation or malfunctions, 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 parameters of the simulation model, so as to realize the online parameter adjustment of the control algorithm.

[0040] During the verification test of the control system, the state parameter signals measured by the sensors are respectively sent to the limiting 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. Based on the switching instruction input by the external input, it selects the control instruction actually output by the speed main control logic and the advanced control algorithm. Finally, the fuel flow control instruction calculated by all sub-control modules is filtered by the maximum and minimum value selector in the original gas turbine controller to select the actual fuel flow instruction. 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 includes Simulink simulation models of core components such as the compressor, turbine, combustion chamber, and shaft. Based on the fuel flow command output by the controller, the simulation model calculates simulated values ​​of the gas turbine's state parameters. The data analysis module determines the performance changes of the gas turbine by calculating the relative error between the measured and simulated values ​​of the state parameters. Then, the data analysis module feeds back the gas turbine's performance changes to the programmable logic controller (PLC). The advanced control algorithm built into the PLC adjusts the gain parameters of the control algorithm according to the performance degradation of the gas turbine, achieving adaptive tracking of the gas turbine's performance state.

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

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

[0044] The programmable logic controller (PLC) host computer is used for programming advanced control algorithms and high-precision mechanistic models of gas turbines, as well as downloading and compiling these models to the PLC. It also features online adjustment of control algorithm parameters. The PLC host computer utilizes a commercial computer and is equipped with software such as MATLAB / Simulink and LabVIEW / Veristand. Control algorithms and gas turbine programs are typically developed based on the MATLAB / Simulink platform. Using features like Simulink Coder, Simulink Real-Time, and Embedded Coder in MATLAB, the graphical model is compiled into binary code that can run on the model simulator and controller (DSP / PLC), enabling rapid development of the gas turbine control system.

[0045] The TC100 commercial gas turbine controller is the manufacturer-installed controller hardware for gas turbine generator sets. It integrates the gas turbine's existing control system, including a main speed controller, limit and protection controllers, and a data acquisition and processing module. It is used to achieve set control objectives, monitor gas turbine performance parameters, and ensure the safe operation of the gas turbine. It is worth noting that this verification platform does not alter the control logic within the TC100 commercial gas turbine controller; it achieves the intended functions through parallel and collaborative control of two controllers.

[0046] The programmable logic controller (PLC) is used to run advanced control algorithms. The PLC is connected in parallel with the commercial TC100 gas turbine controller. The PLC receives measured values ​​of the gas turbine's state parameters after processing by the TC100 controller. The PLC's internal control algorithm calculates the fuel flow command signal based on these measured values ​​and sends it to the TC100 controller. The TC100 controller compares the PLC's control commands with the limiting and protection control commands to determine the final fuel flow command to be sent to the fuel actuator. The PLC and TC100 controller are connected via TCP / IP communication.

[0047] Connections and communication methods of various components of the hardware device:

[0048] The commercial TC100 controller for gas turbines connects to the sensor components of the gas turbine generator set to acquire key performance parameters such as the gas turbine's speed, temperature, pressure, and vibration. The host computer of the original gas turbine controller connects to the commercial TC100 controller via a network cable. The host computer obtains the gas turbine's operating status parameters from the TC100 controller and downloads the compiled control system code to the TC100 controller to achieve parameter tuning of the control system. The host computer of the programmable logic controller (PLC) connects to the PLC via a network cable. The host computer of the PLC uses the built-in software such as MATLAB / Simulink and LabVIEW / Veristand to complete the coding and compilation of advanced control algorithms. The compiled control algorithm code is then downloaded to the PLC via the network cable. During the operation of the programmable logic controller (PLC), on the one hand, the PLC transmits key control performance parameters of the gas turbine to the host computer in real time via network cable, enabling online monitoring of control performance. On the other hand, the host computer can modify the gain parameters of the PLC's internal control algorithm in real time via network cable, achieving online parameter tuning of the control algorithm. The TC100 controller also transmits signals via network cable. The measured values ​​of the gas turbine's state parameters are transmitted from the TC100 controller to the PLC via network cable. The advanced control algorithm within the PLC calculates the corresponding fuel flow control command based on these measured values. Finally, the fuel flow command output by the PLC is transmitted to the TC100 controller via network cable. The TC100 controller, by comparing the fuel flow calculated by its internal control system with the fuel flow transmitted from the PLC, ultimately sends the actual fuel flow command to the fuel actuator, which then outputs actual fuel into the gas turbine's combustion chamber. This completes the entire gas turbine control process.

[0049] Figure 3 This is a flowchart illustrating the implementation of a gas turbine control algorithm based on a dual-controller parallel collaborative architecture. Figure 3 As shown, the implementation steps of this embodiment are as follows:

[0050] Step 1: Based on the design goals and scheme of the gas turbine control system, formulate a 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 gas turbine control system and run the gas turbine stably under no-load conditions;

[0053] Step 4: The commercial TC100 controller for gas turbines acquires the turbine's status parameters in real time;

[0054] Step 5: Check if the gas turbine status parameters are stable and determine if a switch in control is necessary. If yes, proceed to the next step; otherwise, return to step 4.

[0055] Step 6: The instruction selection module receives the switching instruction, the programmable controller starts operation, and calculates the control quantity based on the real-time data of the gas turbine;

[0056] Step 7: The programmable controller outputs control commands to the commercial TC100 controller for gas turbines, which are then transmitted to the actuators for gas turbine control.

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

[0058] Step 9: The instruction selection module receives the switching instruction and switches the control from the programmable controller to the commercial TC100 gas turbine controller. The commercial TC100 gas turbine controller is put into operation to perform gas turbine control operations.

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

[0060] This invention achieves full physical verification of the control algorithm on the existing gas turbine control system through parallel and collaborative control of dual controllers. This minimizes changes to the gas turbine control system, retains the basic architecture of the original control system, and reduces the risks associated with system modification. Simultaneously, it incorporates numerous limiting and protective control logics, such as speed limit protection, surge limit protection, and temperature limit protection, to reduce safety risks during control algorithm testing. This invention enables rapid prototype verification of various advanced control algorithms, meeting the testing requirements of algorithms under different operating conditions. It significantly shortens the process from R&D to engineering application of control algorithms, reduces development time, minimizes verification risks, and is more conducive to the engineering application of advanced control algorithms.

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

Claims

1. A gas turbine control system with a dual-controller parallel cooperative architecture, characterized in that, include: Programmable logic controller (PLC), gas turbine speed main controller, gas turbine limit protection control logic, instruction selection module, minimum value selector, actual gas turbine unit, data acquisition module, gas turbine mechanism simulation model, and data analysis module; The programmable controller is used to run third-party control algorithms and verify the effectiveness of the written control algorithms; The gas turbine speed main controller is the original controller of the gas turbine test unit, which is used to realize speed control during the start-up, load increase / decrease and shutdown processes of the gas turbine foundation; The gas turbine limiting protection control logic is a protection program for the original control system of the gas turbine, used to protect the gas turbine from operating within a safe operating range; The instruction selection module is used to switch between the control instructions calculated by the gas turbine speed main controller and the programmable controller, and to achieve seamless switching between traditional control algorithms and developed third-party control algorithms. Methods for determining whether a change of control is necessary include: The decision to switch the speed controller is based on the operating status of the gas turbine. If the gas turbine is stable, the main speed controller is switched from the original speed controller to a programmable controller, and the developed control algorithm is used to control the gas turbine. If the gas turbine is still unstable, the original speed controller continues to control the gas turbine until the gas turbine is stable, at which point the controller is switched. The minimum value selector is used to determine the actual output value of the protection control logic and the speed main controller's operating command. The actual gas turbine unit is used to receive control command inputs 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 simulated values ​​of the gas turbine output state parameters by receiving fuel flow commands from the gas turbine control system. By comparing the simulated values ​​of the state parameters with the measured values ​​of the sensors, it is determined whether the gas turbine has experienced performance degradation or malfunctions, thereby adjusting the controller parameters to achieve 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, so as to realize the online parameter adjustment of the control algorithm.

2. A method for full physical test verification of a gas turbine control system, characterized in that, include: Based on the design goals and scheme of the gas turbine control system, a test outline and test plan were developed, and the test conditions and implementation steps of the gas turbine were clarified. The control algorithm to be tested is downloaded to the programmable controller, while 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 gas turbine control system and run the gas turbine stably under the set operating conditions; Determine if the parameters of the gas turbine and controller are normal, and determine if it is necessary to switch control. Methods for determining whether a change of control is necessary include: The decision to switch the speed controller is based on the operating status of the gas turbine. If the gas turbine is stable, the main speed controller is switched from the original speed controller to a programmable controller, and the developed control algorithm is used to control the gas turbine. If the gas turbine is still unstable, the original speed controller continues to control the gas turbine until the gas turbine is stable, at which point the controller is switched. The actual gas turbine unit and the gas turbine simulation model simultaneously receive input command signals from the controller and output the measured and simulated values ​​of the gas turbine state parameters, respectively. The data analysis module judges the health status of the unit by comparing the measured and simulated values ​​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 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 procedure.

Images