A layered troubleshooting method for plasma ignition of a marine gas turbine

Abstract

The application relates to the technical field of ship power device fault diagnosis, and discloses a marine gas turbine plasma ignition layered fault checking method, which is characterized by the double-loop structure of the plasma ignition system in a harsh marine environment, and comprises the following steps: firstly, a special safety test environment composed of an insulating box and an observation window is constructed; secondly, the normality of basic energy is confirmed by measuring primary electrical parameters; thirdly, based on the core idea of the control variable method, a hierarchical cross-exchange test process for the aviation plug interface and the igniter body is designed; and fourthly, by comparing the logical changes of the ignition state before and after the exchange, a complete decision tree model is constructed, so that the fault source can be accurately isolated to the control board card, the ignition cable or the igniter. The application converts the experience-dependent troubleshooting process into a standardized and visual technical operation process, and finally effectively solves the problems of low troubleshooting efficiency, high safety risk and great dependence on personnel experience in the prior art.

Description

Technical Field

[0001] This invention relates to the field of marine power plant fault diagnosis technology, specifically a method for troubleshooting stratification faults in marine gas turbine plasma ignition. Background Technology

[0002] As the core power plant of a ship, the reliability of marine gas turbine startup has a decisive impact on navigation safety. The plasma ignition system is a key subsystem ensuring successful startup of the gas turbine, and its operational status directly affects the stability and success rate of the ignition process. However, the marine operating environment is often characterized by high temperature, high humidity, high salt spray, and severe vibration, making electronic components and high-voltage parts in the plasma ignition system more prone to aging, corrosion, and connection failures, leading to system failure. Currently, after ignition failure, troubleshooting this system mainly relies on the experience of maintenance personnel, generally employing a "trial and error" approach for component replacement and testing, lacking a systematic and standardized analysis process. This traditional method has several drawbacks: low efficiency, with indiscriminate replacement of spare parts being time-consuming, especially at sea, potentially delaying troubleshooting and increasing safety risks; poor accuracy, with over-reliance on personal experience leading to misjudgments and inconsistent troubleshooting results; high maintenance costs, with frequent and ineffective spare parts replacements increasing operating and maintenance expenses; and safety hazards, as improper operation during igniter testing could cause injury from high-voltage electricity. Therefore, in order to improve the reliability and maintenance efficiency of marine gas turbine ignition systems, it is urgent to establish a systematic, process-oriented, safe and efficient dedicated fault diagnosis method to achieve rapid and accurate location of faults in plasma ignition systems, thereby effectively ensuring the start-up reliability of marine power systems. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the shortcomings of existing technologies, this invention provides a method for troubleshooting stratified faults in plasma ignition of marine gas turbines. This method is characterized by its strong systematicity, clear logic, standardized operation, high safety, high troubleshooting efficiency, and low dependence on personnel experience. It solves the problems of low fault location efficiency, poor accuracy, high maintenance costs, and high operational risks associated with traditional trial-and-error methods.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for troubleshooting stratification faults in plasma ignition of marine gas turbines, comprising the following steps:

[0007] S1. System Establishment and Composition: Establish a fault diagnosis system, which includes a high-voltage power supply, a first control board, a second control board, a first ignition cable, a second ignition cable, a first igniter, a second igniter, and safety testing and diagnostic auxiliary components.

[0008] S2. Primary electrical verification: Use a voltage measuring device to measure whether the input power supply voltage of the high-voltage power supply pack and the 24VDC ignition command signal voltage from the PLC control system are within the rated threshold range.

[0009] S3. Safety test environment construction and phenomenon observation: The first and second igniters are removed from the gas turbine combustion chamber and installed in a sealed test chamber made of insulating material. The test chamber is equipped with a transparent observation window. Then, an ignition command is sent to the system, and the ignition status of the two igniters is observed and recorded through the observation window.

[0010] S4. Layered Fault Diagnosis: Implement differentiated troubleshooting strategies based on the observation results from step three.

[0011] Preferably, the diagnostic auxiliary component includes an insulation test chamber and a decision support module; the high-voltage power supply, the first control board, and the second control board are all installed inside the plasma igniter box; the ignition cable is connected to the plasma igniter box via an aviation plug, wherein the 24VDC ignition command signal controls the high-voltage output of the high-voltage power supply via the control board.

[0012] Furthermore, the layered fault diagnosis in S4:

[0013] S1.1 When the ignition states of the two igniters are inconsistent, a single-path fault troubleshooting process is executed. This process includes hierarchical testing steps based on interface interchange and component interchange, and the fault point is located by analyzing the logical combination relationship of the test result sequence.

[0014] S1.2 When both igniters fail to ignite, execute the system-level fault diagnosis process, focusing on checking the system-level components of the high-voltage power supply, common power supply, and control signals.

[0015] Furthermore, in S1.1, when the ignition states of the two igniters are inconsistent, and the first igniter ignites while the second igniter does not, the following steps will be performed to eliminate the possibility of inconsistency:

[0016] S1.1.1 Cross-test of board functions: Swap the aviation connectors of the first ignition cable and the second ignition cable at the high-voltage power supply interface of the plasma igniter box, and send the ignition command again and observe:

[0017] (1) When the ignition state changes to the second igniter igniting while the first igniter does not ignite, the second control board is determined to be faulty.

[0018] (2) When the ignition status remains unchanged and the first igniter ignites while the second igniter does not, it is determined that the second control board is functioning normally and the fault is located in the second ignition cable or the second igniter. Then proceed to the next step.

[0019] S1.1.2 Ignition Cross-Test: Swap the installation positions of the first and second igniters in the test box, restore the aviation connector to its original position, and send the ignition command again and observe:

[0020] (1) When the ignition state changes to the second igniter igniting while the first igniter does not ignite, the second igniter is determined to be faulty.

[0021] (2) If the ignition status remains unchanged and the first igniter ignites while the second igniter does not, then the second ignition cable is determined to be faulty.

[0022] Furthermore, in step S1.2, if both igniters fail to ignite, a system-level troubleshooting process is executed, which includes:

[0023] S1.2.1 Common Path Fault Diagnosis: Use a high-voltage probe to measure whether the high-voltage power supply pack has a high-voltage kilovolt output after receiving the ignition command. Specifically:

[0024] (1) When there is no high voltage output, the high voltage power supply unit is determined to be faulty;

[0025] (2) When there is high voltage output, the high voltage power supply is determined to be normal, the fault originates from two independent circuits, and subsequent isolation verification steps are performed.

[0026] S1.2.2, First Circuit Verification: Install the first igniter inside the insulation test box, and ensure that the second igniter and its cable are completely disconnected from the high-voltage power supply; send the ignition command and observe, specifically:

[0027] (1) When the first igniter can ignite, the first circuit is determined to be normal and its status is recorded as normal. Its previous non-ignition status was caused by the second circuit failure.

[0028] (2) When the first igniter fails to ignite, it is determined that there is a real fault in the first circuit and its status is recorded as fault.

[0029] S1.2.3, Second Circuit Verification: Install the second igniter inside the insulation test box, and ensure that the first igniter and its cable are completely disconnected from the high-voltage power supply; send the ignition command and observe, specifically:

[0030] (1) When the second igniter can ignite, the second circuit is determined to be normal and its status is recorded as normal. Its previous non-ignition status was caused by the failure of the first circuit.

[0031] (2) When the second igniter fails to ignite, it is determined that there is a real fault in the second circuit, and its status is recorded as fault.

[0032] S1.2.4 Comprehensive judgment and handling, specifically as follows:

[0033] (1) If the verification results of S1.2.2 first loop verification and S1.2.3 second loop verification show that only one loop is faulty, then the graded test steps of S1.1 above shall be performed separately on the faulty loop to locate the specific fault point inside it.

[0034] (2) If the verification results of S1.2.2 first loop verification and S1.2.3 second loop verification show that both loops have real faults, it is determined to be a multiple fault. The entire plasma igniter box assembly should be replaced first. After replacement, the original igniter and cable should be reinstalled for testing and verification, specifically as follows:

[0035] (1) The process ends when the fault is resolved after verification;

[0036] (2) If the fault still exists, perform the graded test steps of S1.1 above on the two circuits respectively to locate the cable or igniter fault.

[0037] Furthermore, the insulation test chamber has a hexahedral structure and is made of insulating material. One side is provided with an interface for introducing the ignition cable, and the interface needs to be insulated and sealed. At least one side is a transparent observation window for clearly observing the ignition status of the igniter and recording the test results.

[0038] Furthermore, the insulating material is polymethyl methacrylate or polycarbonate, and the thickness of the insulating material of the insulation test box is preferably 4.95-5.05 mm, and the box size is (298-300 mm) × (19-200 mm) × (199-200 mm).

[0039] Furthermore, the decision support module is responsible for receiving the ignition status observation results input by the operator, and automatically analyzing the logical combination relationship of the test result sequence through the built-in algorithm based on the preset hierarchical test step logic relationship, and outputting the fault location conclusion in real time to help the operator avoid ineffective troubleshooting steps and quickly locate the fault point.

[0040] Furthermore, the decision support module is implemented through a software application installed on a tablet computer or a PLC+HMI system. Its built-in logical rule base is constructed based on the hierarchical testing steps of this method, allowing operators to input observation results through a graphical interface and generate fault diagnosis reports and operation instructions in real time.

[0041] Furthermore, the voltage measuring device is a digital multimeter with an accuracy of no less than 0.5 class. When measuring a 220VAC input power supply, its resolution is no less than 0.1V, and when measuring a 24VDC ignition command signal, its resolution is no less than 0.01V. It must also be periodically calibrated. The high-voltage probe is a high-voltage differential probe with a bandwidth of no less than 100MHz and a voltage measurement range covering 0-40kV. When measuring the output of a high-voltage power supply, it must be paired with an oscilloscope with a sampling rate of no less than 1GS / s. The calibration cycle of the probe and the oscilloscope shall not exceed 6 months. At the same time, during the measurement operation, it must be ensured that the length of the probe grounding wire does not exceed 15cm.

[0042] Compared with the prior art, the present invention provides a method for troubleshooting stratification faults in plasma ignition of marine gas turbines, which has the following beneficial effects:

[0043] 1. This invention establishes a systematic inspection system that includes a dedicated insulation test chamber and a decision support module, thereby improving the safety, standardization, and intelligence of the inspection process. The insulation test chamber provides a sealed and insulated physical safety guarantee for high-voltage arcing tests, while the decision support module transforms expert experience into built-in logical rules, guiding operators to operate step by step and automatically outputting diagnostic conclusions, effectively reducing operational risks and excessive reliance on personal experience.

[0044] 2. This invention achieves the beneficial effects of rapidly and accurately locating faulty components and significantly improving troubleshooting efficiency by implementing a progressive process of primary electrical verification, safety testing and observation, and hierarchical cross-diagnosis. This method follows a logical sequence from external to internal and from common causes to unique causes. By controlling variables and cross-interchange testing, it avoids blindly replacing spare parts and can systematically narrow down the scope of the fault, thereby accurately locating the fault point in a short time. It is especially suitable for emergency repair scenarios in ship navigation at sea.

[0045] 3. By clearly defining the technical specifications and operating procedures of key components (such as the accuracy of voltage measuring devices, parameters of high-voltage probes, and the materials and dimensions of the enclosure), this invention achieves the beneficial effects of ensuring the accuracy of measurement data, guaranteeing the reliability of diagnostic conclusions, and reducing overall operation and maintenance costs. The refined technical parameter requirements minimize misjudgments caused by measurement errors, while accurate fault location avoids unnecessary spare parts consumption, saving maintenance costs in the long run and improving equipment availability. Attached Figure Description

[0046] Figure 1 This is a flowchart illustrating the overall process of troubleshooting a gas turbine plasma ignition system according to the present invention.

[0047] Figure 2 This is a detailed flowchart of the single-path fault troubleshooting process (case 2) of the present invention;

[0048] Figure 3 This is a detailed flowchart of the system-level fault diagnosis process (case 3) of the present invention;

[0049] Figure 4 This is a schematic diagram of the insulation test box of the present invention;

[0050] Figure 5 This is a structural block diagram of the fault diagnosis system of the present invention. Detailed Implementation

[0051] The present invention will now be further described with reference to the accompanying drawings.

[0052] Please see Figure 1 - Figure 5 A method for troubleshooting a marine gas turbine plasma ignition system, the system comprising a high-voltage power supply, a first control board, a second control board, a first ignition cable, a second ignition cable, a first igniter, and a second igniter. The high-voltage power supply, the first control board, and the second control board are installed inside the plasma igniter housing. The ignition cable is connected to the plasma igniter housing via an aviation connector. A 24VDC ignition command signal controls the high-voltage output of the high-voltage power supply via the control board. The method includes the following steps:

[0053] S1. Primary electrical verification: Use a voltage measuring device to measure whether the 220VAC input power supply voltage supplied to the high-voltage power pack and the 24VDC ignition command signal voltage from the PLC control system are within the rated threshold range.

[0054] S2. Safety test environment construction and phenomenon observation: The first and second igniters were removed from the gas turbine combustion chamber and installed in a sealed test chamber made of insulating material. The test chamber was equipped with a transparent observation window. Then, an ignition command was sent to the system, and the ignition status of the two igniters was observed and recorded through the observation window.

[0055] S3. Layered Fault Diagnosis: Based on the observations in S2, when the ignition states of the two igniters are inconsistent, a single-path fault troubleshooting process is executed. This process includes tiered testing steps based on interface and component interchangeability, locating the fault point by analyzing the logical combination relationships of the test result sequences. When neither igniter can ignite successfully, a system-level fault troubleshooting process is executed.

[0056] The single-circuit fault troubleshooting process, when the first igniter ignites but the second igniter fails to ignite, includes the following steps:

[0057] S31. Cross-test of board functions: Interchange the aviation plugs of the first ignition cable and the second ignition cable at the high-voltage power supply interface of the plasma igniter box.

[0058] Send the ignition command again and observe:

[0059] When the ignition status changes to the second igniter igniting while the first igniter does not ignite, the second control board is determined to be faulty.

[0060] If the ignition status remains unchanged, and the first igniter ignites while the second igniter does not, then the second control board is deemed to be functioning normally, and the fault is located in the second ignition cable or the second igniter. Proceed to the next step.

[0061] S32, Ignition cross-test: Swap the installation positions of the first ignition and the second ignition in the test box, and restore the aviation plug to its original position before the swap;

[0062] Send the ignition command again and observe:

[0063] When the ignition status changes to the second igniter igniting while the first igniter does not ignite, the second igniter is determined to be faulty.

[0064] If the ignition status remains unchanged, with the first igniter igniting but the second igniter not igniting, then the second ignition cable is considered faulty.

[0065] In step S2, if neither igniter can ignite, a system-level troubleshooting process is executed, which includes:

[0066] S33. Common path fault diagnosis: Use a high-voltage probe to measure whether the high-voltage power supply pack has a high-voltage kilovolt output after receiving the ignition command;

[0067] If there is no high voltage output, the high voltage power supply unit is considered to be faulty.

[0068] When there is high voltage output, the high voltage power supply is determined to be normal, the fault originates from two independent circuits, and subsequent isolation verification steps are executed.

[0069] S34. First Circuit Verification: Install the first igniter inside the insulation test box, and ensure that the second igniter and its cable are completely disconnected from the high-voltage power supply; send the ignition command and observe:

[0070] When the first igniter can ignite, the first circuit is determined to be functioning normally, and its status is recorded as normal. Its previous non-ignition state was caused by a fault in the second circuit.

[0071] If the first igniter fails to ignite, it is determined that there is a real fault in the first circuit, and its status is recorded as fault.

[0072] S35. Second Circuit Verification: Install the second igniter inside the insulation test box, and ensure that the first igniter and its cable are completely disconnected from the high-voltage power supply; send the ignition command and observe:

[0073] When the second igniter can ignite, the second circuit is determined to be functioning normally, and its status is recorded as normal. Its previous non-ignition state was caused by a fault in the first circuit.

[0074] If the second igniter fails to ignite, it is determined that there is a real fault in the second circuit, and its status is recorded as fault.

[0075] S36. Comprehensive Judgment and Handling:

[0076] If the verification results of S34 and S35 show that only one loop is faulty, then the above-mentioned graded test steps are performed separately on the faulty loop to locate the specific fault point inside it.

[0077] If the verification results of S34 and S35 show that there are real faults in both circuits, it is determined to be a multiple fault. The entire plasma igniter box assembly is replaced first. After replacement, the original igniter and cable are reinstalled for testing and verification. When the fault is eliminated after verification, the process ends. If the fault still exists, the above-mentioned graded testing steps are performed on the two circuits respectively to locate the cable or igniter fault.

[0078] A troubleshooting system for implementing the above method includes:

[0079] An insulation test chamber, one side of which is provided with an interface for introducing an ignition cable, and at least one side is a transparent observation window;

[0080] A decision support module is configured to receive the ignition status observation results input by the operator and output the fault location conclusion based on the logical relationship of the preset graded test steps.

[0081] This method addresses the dual-loop structure of plasma ignition systems in harsh marine environments. First, it constructs a dedicated safety testing environment consisting of an insulated enclosure and observation windows. Then, it confirms the basic energy source is functioning correctly by measuring primary electrical parameters. Based on the core idea of ​​the controlled variable method, it designs a tiered cross-interchangeable testing process for aviation plug interfaces and the igniter body. By comparing the logical changes in ignition status before and after the interchange, a complete decision tree model is constructed, thereby accurately isolating the fault source to the smallest replaceable unit (control board, ignition cable, or igniter). This invention transforms the experience-based troubleshooting process into a standardized and visualized technical operation procedure, ultimately effectively solving the problems of low troubleshooting efficiency, high safety risks, and heavy reliance on personnel experience in existing technologies.

[0082] The advantages are: through the integrated configuration of the above-mentioned high-voltage power supply, dual control board, ignition cable and safety testing and diagnostic auxiliary components, combined with the collaborative design of insulation test box and decision support module, the effect of building a complete closed-loop diagnostic system is achieved, providing hardware foundation and logical framework for hierarchical fault diagnosis.

[0083] Specifically, the insulation test chamber has a hexahedral structure to ensure its airtightness and meet the isolation requirements of a safe testing environment. It is made of insulating material, with one side having an interface for introducing the ignition cable. The interface must be insulated and sealed to prevent leakage risks during testing. At least one side is a transparent observation window (made of high-strength insulating transparent material) for clear observation of the ignition status of the igniter, facilitating the operator to record test results.

[0084] The advantages are: through the above-mentioned hexahedral sealed structure, insulating material (polymethyl methacrylate / polycarbonate) and transparent observation window design, it achieves the effect of safely isolating high voltage arc, intuitively observing the arcing status and preventing leakage risk, thus meeting the safety testing requirements in special environments.

[0085] Specifically, the insulating material is polymethyl methacrylate or polycarbonate. The thickness of the insulating material in the insulation test chamber is preferably 4.95 to 5.05 mm, and the chamber size is (298 to 300 mm) × (19 to 200 mm) × (199 to 200 mm) to meet the installation requirements of the igniter and ensure operational safety.

[0086] Specifically, the decision support module is responsible for receiving the ignition status observation results input by the operator (such as the first igniter igniting / the second igniter not igniting and the change in ignition status after swapping). Based on the preset hierarchical test step logic relationship (such as the judgment rule that if the state is reversed after swapping in the cross-test of the board, the board is judged to be faulty; if the state is reversed after swapping in the cross-test of the igniter, the igniter is judged to be faulty), it automatically analyzes the logical combination relationship of the test result sequence through the built-in algorithm, and outputs the fault location conclusion in real time (such as the second control board fault and the second ignition cable fault), to help the operator avoid ineffective troubleshooting steps and quickly locate the fault point.

[0087] Specifically, the decision support module is implemented through a software application installed on a tablet or a PLC+HMI system. Its built-in logical rule base is built based on the hierarchical testing steps of this method, allowing operators to input observation results through a graphical interface and generate fault diagnosis reports and operation instructions in real time.

[0088] The advantages are: through the above-mentioned pre-set logical rule base, graphical interface input and real-time fault conclusion output, it can achieve the effect of automatically analyzing test result sequences, avoiding ineffective troubleshooting steps and quickly locating fault points, significantly reducing the dependence on personnel experience.

[0089] Specifically, the voltage measuring device is a digital multimeter with an accuracy of no less than 0.5 class. When measuring 220VAC input power, its resolution is no less than 0.1V, and when measuring 24VDC ignition command signal, its resolution is no less than 0.01V. It must also be periodically (every 3 months) calibrated to ensure the accuracy of voltage data during the primary electrical verification stage and avoid misjudgment of faults due to measurement errors.

[0090] The advantages are: by using the high-precision digital multimeter (0.5-level accuracy), multiple resolutions, and regular metrological calibration, the 220VAC input power supply and 24VDC command signal can be accurately measured, ensuring the reliability of data in the initial electrical verification stage and avoiding misjudgments due to measurement errors.

[0091] Specifically, the high-voltage probe is a high-voltage differential probe with a bandwidth of not less than 100MHz and a voltage measurement range covering 0-40kV. When measuring the output of a high-voltage power supply, it must be paired with an oscilloscope with a sampling rate of not less than 1GS / s, and the calibration cycle of the probe and the oscilloscope should not exceed 6 months. At the same time, during the measurement operation, it must be ensured that the length of the probe grounding wire does not exceed 15cm to reduce the influence of external electromagnetic interference on the kilovolt-level voltage measurement results and ensure the reliability of high-voltage output judgment.

[0092] The advantages are: through the above-mentioned wide bandwidth (≥100MHz), high sampling rate (≥1GS / s) high voltage differential probe and short grounding wire design, the electromagnetic interference is suppressed and the high voltage pulse signal is accurately captured, ensuring the reliability of high voltage output judgment.

[0093] For details, please refer to Figure 1 The overall process of this method begins with receiving an ignition failure signal. The first step (S1) is to perform a primary electrical verification by using a multimeter and other general electrical tools to measure whether the voltage values ​​of the 220VAC power supply and the 24VDC command are within the normal range. This step is the basis for all subsequent diagnostics and can effectively rule out external power supply problems.

[0094] After confirming that the power supply is normal, proceed to S2 to build the security test environment. Please refer to [link / reference]. Figure 4 The insulation test box 1 is preferably made of 5mm thick transparent acrylic sheet (polymethyl methacrylate) bonded together, with a size of approximately 300mm×200mm×200mm. A circular observation window 2 is opened at the front of the box, and two standard cable interface holes 3 are reserved on the rear side of the box for introducing the ignition cable 4 into the box and connecting the igniter 5. This design is a special safety protection device designed for the high-voltage ignition characteristics of plasma igniters, which can ensure the visibility and safety of the test process. This step is the basic prerequisite and physical guarantee for realizing all subsequent graded test steps.

[0095] Based on the observations from S2, the cases were diverted to different investigation paths.

[0096] Scenario 2 (Single-channel failure): For a detailed explanation of the troubleshooting process, please refer to [link / reference]. Figure 2 The core of this step lies in controlling variables and hierarchical cross-testing.

[0097] Scenario 3 (Dual-path failure): Please refer to [link / reference] Figure 3 When neither igniter works, first check the common part, use a high-voltage probe to measure the output of the high-voltage power supply, and then start the complete isolation verification process (S34-S36) to systematically identify and locate the fault in the dual circuit.

[0098] The advantages are: through the above-mentioned control variable method, hierarchical cross-testing and dual-path fault isolation verification process, the fault range can be systematically narrowed and the single / dual-path fault scenarios can be covered, realizing a logical investigation from phenomenon to root cause.

[0099] Example (taking a certain type of marine gas turbine plasma ignition system as an example)

[0100] Example of primary electrical verification: In step S1, the rated threshold range is: the normal range of 220VAC input power is set to 198VAC~242VAC; the normal range of 24VDC ignition command is set to 22.8VDC~25.2VDC. The measurement is performed at the external power interface supplying the plasma igniter box, the purpose of which is to confirm that the power and command have been delivered normally.

[0101] Operating procedure of the insulation test chamber: The internal space of the insulation test chamber can accommodate two igniters. The operator can install the igniters to be tested into the chamber one by one for observation (e.g., test A first and then B), or place two igniters simultaneously.

[0102] Supplementary procedure for high voltage measurement: In step S33, use a high voltage probe (such as Tektronix P6015A) connected to an oscilloscope for measurement. When the measured pulse voltage is lower than 8kV (example value), it is determined that there is no high voltage output.

[0103] Example of implementing a decision support module: The decision support module is a software application installed on a tablet computer. After the operator selects and executes a certain step on the interface and observes the phenomenon, the program automatically calls the preset logic rule base and outputs the fault location conclusion (such as "Fault point: B control board") and prompts for the next operation. This module can also be implemented by PLC+HMI.

[0104] In summary, through the above-mentioned systematic troubleshooting process design, innovative application of dedicated safety testing devices, precise definition of key parameters, and introduction of intelligent decision support, the traditional experience-based, vague troubleshooting has been transformed into standardized, traceable, and accurate diagnosis. Ultimately, this achieves the comprehensive goals of ensuring personnel safety, improving troubleshooting efficiency, reducing operation and maintenance costs, and enhancing the start-up reliability of gas turbines.

Claims

1. A method for troubleshooting stratification faults in plasma ignition of marine gas turbines, characterized in that, Includes the following steps: S1. System Establishment and Composition: Establish a fault diagnosis system, which includes a high-voltage power supply, a first control board, a second control board, a first ignition cable, a second ignition cable, a first igniter, a second igniter, and safety testing and diagnostic auxiliary components. The diagnostic support components include an insulation test chamber and a decision support module; S2. Primary electrical verification: Use a voltage measuring device to measure whether the input power supply voltage of the high-voltage power supply pack and the 24VDC ignition command signal voltage from the PLC control system are within the rated threshold range. S3. Safety test environment construction and phenomenon observation: The first and second igniters are removed from the gas turbine combustion chamber and installed in a sealed test chamber made of insulating material. The test chamber is equipped with a transparent observation window. Then, an ignition command is sent to the system, and the ignition status of the two igniters is observed and recorded through the observation window. S4. Layered Fault Diagnosis: Implement differentiated troubleshooting strategies based on the observation results from step three; Layered fault diagnosis: S1.1 When the ignition states of the two igniters are inconsistent, a single-path fault troubleshooting process is executed. This process includes hierarchical testing steps based on interface interchange and component interchange, and the fault point is located by analyzing the logical combination relationship of the test result sequence. S1.2 When both igniters fail to ignite, execute the system-level fault diagnosis process, focusing on checking the system-level components of the high-voltage power supply, common power supply, and control signals. In step S1.1, if the ignition states of the two igniters are inconsistent, and the first igniter ignites while the second igniter does not, the following steps will be performed to eliminate the problem: S1.1.1 Cross-test of board functions: Swap the aviation connectors of the first ignition cable and the second ignition cable at the high-voltage power supply interface of the plasma igniter box, and send the ignition command again and observe: (1) When the ignition state changes to the second igniter igniting while the first igniter does not ignite, the second control board is determined to be faulty. (2) When the ignition status remains unchanged and the first igniter ignites while the second igniter does not, it is determined that the second control board is functioning normally and the fault is located in the second ignition cable or the second igniter, and the next step is executed. S1.1.2 Ignition Cross-Test: Swap the installation positions of the first and second igniters in the test box, restore the aviation connector to its original position, and send the ignition command again and observe: (1) When the ignition state changes to the second igniter igniting while the first igniter does not ignite, the second igniter is determined to be faulty. (2) If the ignition status remains unchanged and the first igniter ignites while the second igniter does not, then the second ignition cable is considered to be faulty.

2. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: The high-voltage power supply, the first control board, and the second control board are all installed inside the plasma igniter box; the ignition cable is connected to the plasma igniter box via an aviation plug, wherein the 24VDC ignition command signal controls the high-voltage output of the high-voltage power supply via the control board.

3. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: In step S1.2, if both igniters fail to ignite, a system-level troubleshooting process is executed, which includes: S1.2.1 Common Path Fault Diagnosis: Use a high-voltage probe to measure whether the high-voltage power supply pack has a high-voltage kilovolt output after receiving the ignition command. Specifically: (1) When there is no high voltage output, the high voltage power supply unit is determined to be faulty; (2) When there is high voltage output, it is determined that the high voltage power supply is normal, the fault originates from two independent circuits, and subsequent isolation verification steps are performed. S1.2.2, First Circuit Verification: Install the first igniter inside the insulation test box, and ensure that the second igniter and its cable are completely disconnected from the high-voltage power supply; send the ignition command and observe, specifically: (1) When the first igniter can ignite, the first circuit is deemed to be functioning normally and its status is recorded as normal. Its previous non-ignition status was caused by a fault in the second circuit. (2) When the first igniter fails to ignite, it is determined that there is a real fault in the first circuit and its status is recorded as fault. S1.2.3, Second Circuit Verification: Install the second igniter inside the insulation test box, and ensure that the first igniter and its cable are completely disconnected from the high-voltage power supply; send the ignition command and observe, specifically: (1) When the second igniter can ignite, the second circuit is deemed to be functioning normally and its status is recorded as normal. Its previous non-ignition status was caused by a fault in the first circuit. (2) When the second igniter fails to ignite, it is determined that there is a real fault in the second circuit, and its status is recorded as fault; S1.2.4 Comprehensive judgment and handling, specifically as follows: (1) If the verification results of S1.2.2 first loop verification and S1.2.3 second loop verification show that only one loop is faulty, then the graded test steps of S1.1 above shall be performed separately on the faulty loop to locate the specific fault point inside it. (2) If the verification results of S1.2.2 first loop verification and S1.2.3 second loop verification show that there are real faults in both loops, it is determined to be a multiple fault. The entire plasma igniter box assembly should be replaced first. After replacement, the original igniter and cable should be reinstalled for testing and verification, specifically: (1) The process ends when the fault is resolved after verification; (2) If the fault still exists, perform the graded test steps of S1.1 above on the two circuits respectively to locate the cable or igniter fault.

4. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: The insulation test chamber has a hexahedral structure and is made of insulating material. One side is provided with an interface for introducing the ignition cable, and the interface needs to be insulated and sealed. At least one side is a transparent observation window for clearly observing the ignition status of the igniter and recording the test results.

5. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: The insulating material is polymethyl methacrylate or polycarbonate. The thickness of the insulating material of the insulating test box is preferably 4.95-5.05 mm, and the box size is (298-300 mm) × (19-200 mm) × (199-200 mm).

6. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: The decision support module is responsible for receiving the ignition status observation results input by the operator, and automatically analyzing the logical combination relationship of the test result sequence through the built-in algorithm based on the preset hierarchical test step logic relationship. It outputs the fault location conclusion in real time, helping the operator to avoid ineffective troubleshooting steps and quickly locate the fault point.

7. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: The decision support module is implemented through a software application installed on a tablet computer or a PLC+HMI system. Its built-in logical rule base is built based on the hierarchical testing steps of this method, allowing operators to input observation results through a graphical interface and generate fault diagnosis reports and operation instructions in real time.

8. The method for troubleshooting stratification faults in plasma ignition of marine gas turbines according to claim 1, characterized in that: The voltage measuring device is a digital multimeter with an accuracy of no less than 0.5 class. When measuring 220VAC input power, its resolution is no less than 0.1V, and when measuring 24VDC ignition command signal, its resolution is no less than 0.01V. It must also be periodically calibrated. The high-voltage probe is a high-voltage differential probe with a bandwidth of no less than 100MHz and a voltage measurement range covering 0-40kV. When measuring the output of the high-voltage power supply, it must be paired with an oscilloscope with a sampling rate of no less than 1GS / s. The calibration cycle of the probe and the oscilloscope shall not exceed 6 months. At the same time, during the measurement operation, it must be ensured that the length of the probe grounding wire does not exceed 15cm.

Images