Thermocouple temperature monitoring system and method based on dynamic sorting and fault detection
The thermocouple temperature monitoring method with dynamic sequencing and fault detection solves the accuracy problem of low-pressure turbine exhaust temperature monitoring technology, realizes accurate detection of the combustion system, and ensures the safe operation of the gas turbine.
Patent Information
- Application Number
- CN202510862506.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-25
- Publication Date
- 2025-09-16
AI Technical Summary
Existing low-pressure turbine exhaust temperature monitoring technology has poor accuracy, resulting in poor accuracy in indirect detection of the combustion system, and is unable to effectively exclude faulty sensors and account for adjacent thermocouple failures.
A thermocouple temperature monitoring method based on dynamic sorting and fault detection is adopted. Temperature values are collected through multiple thermocouple sensors, abnormal data is removed, and response delay correction processing is performed. After sorting, the median or average value is calculated as a reference value, and the difference between adjacent sensors is detected to see if it exceeds the threshold to determine if the combustion system fails.
The accuracy of low-pressure turbine exhaust temperature monitoring is improved, local over-temperature anomalies in the combustion system are discovered in a timely manner, and the safe operation of the equipment is ensured.
Smart Images
Figure CN120651371A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of gas turbine fault detection. Background Art
[0002] Figure 1 This is a working principle diagram of a simple cycle gas turbine unit. Because the temperature of the combustion system is extremely high, generally reaching above 1200°C, it is difficult to measure it directly with a thermocouple sensor. Therefore, it is necessary to measure the exhaust temperature of the low-pressure turbine to indirectly detect whether the combustion system has an over-temperature fault. Existing low-pressure turbine exhaust temperature monitoring technology usually uses the following methods:
[0003] Direct average method: The average temperature value of all thermocouples is taken as the monitoring temperature. The disadvantage is that it cannot detect local temperature anomalies.
[0004] Faulty sensors have a significant impact: The direct averaging method cannot effectively eliminate faulty sensors, resulting in distorted monitored temperature.
[0005] Insufficient adjacent fault detection: Existing technologies do not fully consider the situation of adjacent thermocouple failures, which may result in local temperature anomalies not being discovered in time.
[0006] Therefore, the existing low-pressure turbine exhaust temperature monitoring technology has poor accuracy, resulting in poor accuracy in indirect detection of the combustion system. Summary of the Invention
[0007] The purpose of the present invention is to solve the problem of poor accuracy of existing low-pressure turbine exhaust temperature monitoring technology, which leads to poor accuracy of indirect detection of combustion system. A thermocouple temperature monitoring system and method based on dynamic sorting and fault detection is proposed.
[0008] A thermocouple temperature monitoring method based on dynamic sequencing and fault detection, wherein multiple thermocouple sensors are used to collect multiple low-pressure turbine exhaust temperature values, is characterized in that the method includes the following contents:
[0009] Step 1: Collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time, remove low-pressure turbine exhaust temperature values that are disconnected or exceed a preset range, and retain the low-pressure turbine exhaust temperature values as valid data;
[0010] Step 2: The valid data is subjected to response delay correction processing to obtain a plurality of corrected low-pressure turbine exhaust temperature values;
[0011] Step 3: sorting the multiple corrected low-pressure turbine exhaust temperature values from high to low to obtain sorted temperature values, and selecting a median value therefrom. If the median value is two temperature values, then taking the average of the two temperature values as the gas turbine exhaust temperature reference value; if the median value is one temperature value, then taking the average of the two temperature values as the gas turbine exhaust temperature reference value;
[0012] Step 4: Subtract the sorted temperature values from the gas turbine exhaust temperature reference value in sequence, collect the serial numbers of multiple thermocouple sensors, and detect whether the differences corresponding to the serial numbers of a preset number of adjacent thermocouple sensors all exceed the preset deviation threshold. If so, it is determined that the combustion system has an overtemperature fault and the gas turbine is controlled to shut down. If not, it is determined that the combustion system is operating normally.
[0013] Preferably, step 4 further includes:
[0014] The thermocouple sensor corresponding to the difference value exceeding the preset deviation threshold is determined to be a faulty sensor.
[0015] Preferably, in step 2, the response delay correction process is:
[0016] ;
[0017] Where MID_TX is the corrected low-pressure turbine exhaust temperature value, T4 is the multiple low-pressure turbine exhaust temperature values currently collected and output by the thermocouple sensor, BT4 is the multiple low-pressure turbine exhaust temperature values collected and output by the thermocouple sensor at the previous moment, and K is the correction coefficient.
[0018] Preferably, in step 4, the preset deviation threshold is 25°C.
[0019] Preferably, the preset number is 3.
[0020] A system for detecting combustion system faults using dynamic sequencing of thermocouple temperatures, the system comprising a quality verification module, a correction module, a reference value calculation module, and a combustion system fault detection module;
[0021] The quality verification module is used to collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time, remove the low-pressure turbine exhaust temperature values with a temperature value of 0 or exceeding a preset range, and transmit the retained low-pressure turbine exhaust temperature values as valid data to the correction module;
[0022] a correction module, configured to correct the valid data to obtain a plurality of corrected low-pressure turbine exhaust temperature values and transmit the corrected values to the reference value calculation module;
[0023] a reference value calculation module, configured to sort the multiple corrected low-pressure turbine exhaust temperature values from high to low to obtain multiple sorted temperature values, select a median value from the sorted temperature values, and if the median value is two temperature values, take the average of the two temperature values as the gas turbine exhaust temperature reference value; if the median value is one temperature value, take the valid data as the gas turbine exhaust temperature reference value and transmit it to the combustion system fault detection module;
[0024] The combustion system fault detection module is used to sequentially subtract the sorted temperature values from the reference value of the gas turbine exhaust temperature, collect the serial numbers of multiple thermocouple sensors, and detect whether the differences corresponding to the serial numbers of a preset number of adjacent thermocouple sensors all exceed a preset deviation threshold. If so, it is determined that the combustion system has an over-temperature fault and the gas turbine is controlled to shut down. If not, it is determined that the combustion system is operating normally.
[0025] Preferably, the system further comprises a thermocouple sensor fault detection module;
[0026] The thermocouple sensor fault detection module determines that the thermocouple sensor corresponding to the difference value exceeding the preset deviation threshold is a faulty sensor.
[0027] The beneficial effects of the present invention are:
[0028] The present invention uses response delay correction processing on valid data to correct the response delay phenomenon caused by data transmission delay, thereby ensuring the accuracy of temperature monitoring; then the corrected data is sorted to reduce the computational complexity; finally, it is detected whether there is a preset number of adjacent differences that exceed a preset deviation threshold, thereby promptly discovering local over-temperature anomalies in the combustion system and ensuring the safe operation of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Figure 1 This is the working principle diagram of a simple cycle unit of a gas turbine;
[0030] Figure 2 The figure is a flow chart of a thermocouple temperature monitoring method based on dynamic sequencing and fault detection;
[0031] Figure 3 This is the layout diagram of the thermocouple sensor. DETAILED DESCRIPTION
[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.
[0033] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but they are not intended to limit the present invention.
[0034] Example 1:
[0035] A thermocouple temperature monitoring method based on dynamic sequencing and fault detection, wherein multiple thermocouple sensors are used to collect multiple low-pressure turbine exhaust temperature values, is characterized in that the method includes the following contents:
[0036] Step 1: Collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time, remove low-pressure turbine exhaust temperature values that are disconnected or exceed a preset range, and retain the low-pressure turbine exhaust temperature values as valid data;
[0037] Step 2: The valid data is subjected to response delay correction processing to obtain a plurality of corrected low-pressure turbine exhaust temperature values;
[0038] Step 3: sorting the multiple corrected low-pressure turbine exhaust temperature values from high to low to obtain sorted temperature values, and selecting a median value therefrom. If the median value is two temperature values, then taking the average of the two temperature values as the gas turbine exhaust temperature reference value; if the median value is one temperature value, then taking the average of the two temperature values as the gas turbine exhaust temperature reference value;
[0039] Step 4: Subtract the sorted temperature values from the gas turbine exhaust temperature reference value in sequence, collect the serial numbers of multiple thermocouple sensors, and detect whether the differences corresponding to the serial numbers of a preset number of adjacent thermocouple sensors all exceed the preset deviation threshold. If so, it is determined that the combustion system has an overtemperature fault and the gas turbine is controlled to shut down. If not, it is determined that the combustion system is operating normally.
[0040] Specifically, in step 1, an acquisition card is used to collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time. Low-pressure turbine exhaust temperature values that are disconnected or exceed a preset range are automatically removed. Low-pressure turbine exhaust temperature values that exceed the preset range are considered out-of-range data, indicating that the thermocouple sensor itself has low measurement precision and inaccurate measurements. Therefore, disconnected or out-of-range temperatures are first removed. The removed data can be marked as invalid (disconnected or out-of-range) and a specific value (-500).
[0041] If there are 16 thermocouple sensors in total, the 16 thermocouple sensor data (T4_01-T4_16) are sorted from high to low every second, and combined with the index records, the original position of the corresponding temperature value after sorting can be quickly determined.
[0042] Based on the sorting results, the median value is dynamically calculated and used as a reference value for the low-pressure turbine exhaust temperature to ensure the accuracy of the monitored temperature.
[0043] Calculation of median value: If the data of 16 sensors are valid, take the average value of the middle position (T4_08 and T4_09) as the reference value of gas turbine exhaust temperature.
[0044] If the data from 15 sensors are valid, take T4_08 as the reference value of the gas turbine exhaust temperature.
[0045] If the data from 14 sensors are valid, take the average value of the middle position (T4_07 and T4_08) as the reference value of the gas turbine exhaust temperature.
[0046] If the data from all 13 sensors are valid, use T4_07 as the reference value for the gas turbine exhaust temperature. Calculate the median value in this way.
[0047] If the difference between the adjacent preset number of values exceeds the preset deviation threshold, it means that the temperature in this combustion area is generally too high or too low, the combustion is uneven, and the exhaust temperature dispersion is large. It can be inferred that the exhaust temperature field may be uneven due to damage to a combustion chamber, and the engine should be shut down immediately for protection. Figure 3 If the thermocouple sensor numbered T4-01 is a disconnected sensor, the difference of this sensor is not calculated. It is determined whether the differences of three adjacent sensors among the differences of other sensors exceed the threshold. For example, it is determined whether the differences of T4-02 to T4-04 among the differences numbered T4-02 to T4-16 all exceed the threshold, and whether the differences of T4-03 to T4-05 all exceed the threshold.
[0048] A gas turbine is a power machine that operates using internal combustion. A continuously flowing gas (typically high-temperature, high-pressure gas) drives a high-speed impeller, converting the fuel's energy into mechanical energy. A gas turbine primarily consists of three core components: a compressor, a combustion chamber, and a turbine. The turbine is a key component of the gas turbine, responsible for converting the high-temperature, high-pressure gas energy into mechanical work. Turbines can be divided into high-pressure and low-pressure turbines based on their location and function.
[0049] Further defining, step 4 also includes:
[0050] The thermocouple sensor corresponding to the difference value exceeding the preset deviation threshold is determined to be a faulty sensor.
[0051] Specifically, multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors are collected once per second, and the position labels of the thermocouple sensors corresponding to the corresponding temperature values are recorded so as to subsequently detect the position of the faulty thermocouple sensor.
[0052] A dynamic sorting algorithm is used to sort the data from high to low every second. Combined with the index record, the original position of the corresponding temperature value after sorting can be quickly determined.
[0053] Further defined, in step 2, the response delay correction process is:
[0054] ;
[0055] Where MID_TX is the corrected low-pressure turbine exhaust temperature value, T4 is the multiple low-pressure turbine exhaust temperature values currently collected and output by the thermocouple sensor, BT4 is the multiple low-pressure turbine exhaust temperature values collected and output by the thermocouple sensor at the previous moment, and K is the correction coefficient.
[0056] Specifically, because there's a response delay between the thermocouple sensor and the controller processing data, a temperature correction process is required to compensate for this delay. The correction factor, K, adjusts the impact of the rate of change on the correction value, with a value of 0.8 being recommended. The K factor can be adjusted in conjunction with the temperature rate of change to accommodate temperature fluctuations and environmental changes.
[0057] It is further defined that in step 4, the preset deviation threshold is 25°C.
[0058] Further limited, the preset number is 3.
[0059] Example 2:
[0060] A thermocouple temperature monitoring system based on dynamic sequencing and fault detection, the system comprising a quality verification module, a correction module, a reference value calculation module and a combustion system fault detection module;
[0061] The quality verification module is used to collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time, remove the low-pressure turbine exhaust temperature values that are broken or exceed the preset range, and transfer the retained low-pressure turbine exhaust temperature values as valid data to the correction module;
[0062] a correction module, configured to correct the valid data to obtain a plurality of corrected low-pressure turbine exhaust temperature values and transmit the corrected values to the reference value calculation module;
[0063] a reference value calculation module, configured to sort the multiple corrected low-pressure turbine exhaust temperature values from high to low to obtain multiple sorted temperature values, select a median value from the sorted temperature values, and if the median value is two temperature values, take the average of the two temperature values as the gas turbine exhaust temperature reference value; if the median value is one temperature value, take the valid data as the gas turbine exhaust temperature reference value and transmit it to the combustion system fault detection module;
[0064] The combustion system fault detection module is used to sequentially subtract the sorted temperature values from the reference value of the gas turbine exhaust temperature, collect the serial numbers of multiple thermocouple sensors, and detect whether the differences corresponding to the serial numbers of a preset number of adjacent thermocouple sensors all exceed a preset deviation threshold. If so, it is determined that the combustion system has an over-temperature fault and the gas turbine is controlled to shut down. If not, it is determined that the combustion system is operating normally.
[0065] It is further defined that the system further includes a thermocouple sensor fault detection module;
[0066] The thermocouple sensor fault detection module determines that the thermocouple sensor corresponding to the difference value exceeding the preset deviation threshold is a faulty sensor.
[0067] Although the present invention is described herein with reference to specific embodiments, it should be understood that these embodiments are merely illustrative of the principles and applications of the invention. It should be understood that many modifications may be made to the illustrative embodiments, and that other arrangements may be devised, without departing from the spirit and scope of the invention as defined by the appended claims. It should be understood that the various dependent claims and features described herein may be combined in ways other than those described in the original claims. It should also be understood that features described in conjunction with individual embodiments may be employed in conjunction with other described embodiments.
Claims
1. A thermocouple temperature monitoring method based on dynamic sorting and fault detection, wherein multiple thermocouple sensors are used to collect multiple low-pressure turbine exhaust temperature values, characterized in that: The method includes the following: Step 1: Collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time, remove low-pressure turbine exhaust temperature values that are disconnected or exceed a preset range, and retain the low-pressure turbine exhaust temperature values as valid data; Step 2: The valid data is subjected to response delay correction processing to obtain a plurality of corrected low-pressure turbine exhaust temperature values; Step 3: sorting the multiple corrected low-pressure turbine exhaust temperature values from high to low to obtain sorted temperature values, and selecting a median value therefrom. If the median value is two temperature values, then taking the average of the two temperature values as the gas turbine exhaust temperature reference value; if the median value is one temperature value, then taking the average of the two temperature values as the gas turbine exhaust temperature reference value; Step 4: Subtract the sorted temperature values from the gas turbine exhaust temperature reference value in sequence, collect the serial numbers of multiple thermocouple sensors, and detect whether the differences corresponding to the serial numbers of a preset number of adjacent thermocouple sensors all exceed the preset deviation threshold. If so, it is determined that the combustion system has an overtemperature fault and the gas turbine is controlled to shut down. If not, it is determined that the combustion system is operating normally.
2. The thermocouple temperature monitoring method based on dynamic sorting and fault detection according to claim 1, characterized in that: Step 4 also includes: The thermocouple sensor corresponding to the difference value exceeding the preset deviation threshold is determined to be a faulty sensor.
3. The method for detecting combustion system failures using dynamic sequencing of thermocouple temperatures according to claim 1, characterized in that: In step 2, the response delay correction process is as follows: ； Where MID_TX is the corrected low-pressure turbine exhaust temperature value, T4 is the multiple low-pressure turbine exhaust temperature values currently collected and output by the thermocouple sensor, BT4 is the multiple low-pressure turbine exhaust temperature values collected and output by the thermocouple sensor at the previous moment, and K is the correction coefficient.
4. The thermocouple temperature monitoring method based on dynamic sorting and fault detection according to claim 1, characterized in that: In step 4, the preset deviation threshold is 25°C.
5. The thermocouple temperature monitoring method based on dynamic sorting and fault detection according to claim 2, characterized in that: The default number is 3.
6. Thermocouple temperature monitoring system based on dynamic sorting and fault detection, characterized in that: The system includes a quality verification module, a correction module, a reference value calculation module and a combustion system fault detection module; The quality verification module is used to collect multiple low-pressure turbine exhaust temperature values output by multiple thermocouple sensors at the same time, remove the low-pressure turbine exhaust temperature values that are broken or exceed the preset range, and transfer the retained low-pressure turbine exhaust temperature values as valid data to the correction module; a correction module, configured to correct the valid data to obtain a plurality of corrected low-pressure turbine exhaust temperature values and transmit the corrected values to the reference value calculation module; a reference value calculation module, configured to sort the multiple corrected low-pressure turbine exhaust temperature values from high to low to obtain multiple sorted temperature values, select a median value from the sorted temperature values, and if the median value is two temperature values, take the average of the two temperature values as the gas turbine exhaust temperature reference value; if the median value is one temperature value, take the valid data as the gas turbine exhaust temperature reference value and transmit it to the combustion system fault detection module; The combustion system fault detection module is used to sequentially subtract the sorted temperature values from the reference value of the gas turbine exhaust temperature, collect the serial numbers of multiple thermocouple sensors, and detect whether the differences corresponding to the serial numbers of a preset number of adjacent thermocouple sensors all exceed a preset deviation threshold. If so, it is determined that the combustion system has an over-temperature fault and the gas turbine is controlled to shut down. If not, it is determined that the combustion system is operating normally.
7. The thermocouple temperature monitoring system based on dynamic sequencing and fault detection according to claim 6, characterized in that: The system also includes a thermocouple sensor fault detection module; The thermocouple sensor fault detection module determines that the thermocouple sensor corresponding to the difference value exceeding the preset deviation threshold is a faulty sensor.