Water-turbine generator set waterless electromechanical joint debugging startup and shutdown process test system and method

Abstract

The invention discloses a water-turbine generator set waterless electromechanical joint debugging startup and shutdown process test system and method. The system comprises a simulation test model and a test platform. The simulation test model comprises a basic parameter layer, a logic rule layer and a historical working condition layer; the test platform comprises a state recording module, a condition enforcement module, a data import module and an abnormality diagnosis module. The method comprises the following steps: importing recent operation data, recording an initial state, forcibly setting unsatisfied conditions, executing startup and shutdown, and finally automatically generating a standardized test report by utilizing machine learning and mechanism model combined diagnosis abnormity, defect elimination, forcibility relief and state comparison. The machine-electricity-control cooperative performance can be comprehensively verified in the water-free stage, hidden dangers are exposed in advance, the debugging period is shortened, the rectification risk after water filling is reduced, and the modular joint debugging requirements of units of different scales are met.

Description

Technical Field

[0001] This invention relates to the field of hydropower generation technology, and in particular to a test system and method for the start-up and shutdown process of a hydropower generator set without water turbines. Background Technology

[0002] Hydropower turbine generator sets are the core equipment of hydropower systems, and the reliability of their start-up and shutdown processes directly affects the power plant's power generation efficiency and safe operation. With the in-depth application of intelligent technologies in the hydropower field, intelligent start-up and shutdown processes achieve precise start-up and shutdown of the units through automated control, sensor monitoring, and logic algorithms. However, rigorous testing is required before they can be put into actual operation.

[0003] Hydropower generator unit dewatered electromechanical commissioning involves jointly debugging the electrical, mechanical, and automation systems of the unit without water. This allows for the early detection of design or installation problems in the electrical, mechanical, and control systems, preventing downtime and accidents caused by malfunctions during commissioning after water filling. It also ensures that the interfaces of each system are compatible and that the logic linkages are normal, laying the foundation for subsequent water filling tests and load operation, and guaranteeing the safe and stable operation of the unit after commissioning.

[0004] The main commissioning contents include: electrical system commissioning: checking the wiring, protection devices and control circuits of electrical equipment such as generators, transformers, and circuit breakers; testing the functions of the excitation system and synchronizing device to ensure that electrical parameters meet design requirements; mechanical system inspection: debugging the flexibility of mechanical components such as speed governors and relays; checking the operating status of bearing lubrication and cooling systems; and confirming that the pressure values ​​of each system of the unit are normal; automation system commissioning: linking and testing the unit's automation control process, including the logical correctness of operations such as start-up, shutdown, and load increase / decrease, and verifying the communication compatibility between the PLC (Programmable Logic Controller) program and each device; and protection function verification: simulating various faults (such as turbine accidents (low oil pressure, cylinder valve slippage, main shaft sealing water interruption), generator accidents, overspeed, etc.) to test the accuracy and timeliness of the protection devices, ensuring that the unit can automatically shut down for protection under abnormal operating conditions.

[0005] The existing hydro-turbine generator unit start-up and shutdown tests have the following deficiencies: 1. Traditional experiments often rely on manual operation on existing monitoring systems and judgment based on work instructions and experience, which makes it difficult to conduct a comprehensive review and prevents potential risks from being exposed.

[0006] 2. The test process lacked real-time and accurate monitoring and systematic analysis of the status of each system of the turbine unit, as well as the bearing levels and temperatures of the three turbine parts, the water pressure of the volute, the tailrace pressure, the top cover level, the high-pressure oil operation, the event signals and key parameters of each system, resulting in low efficiency in process optimization.

[0007] 3. The testing process lacks standardization and modular design, making it difficult to meet the personalized testing needs of different models and scales of hydro-generator units. Summary of the Invention

[0008] To address the aforementioned issues, this invention provides a test system and method for the start-up and shutdown process of a hydro-generator unit without water, enabling comprehensive verification of the start-up and shutdown process of the hydro-generator unit without water, quickly locating and resolving potential problems in the process, improving the reliability and efficiency of unit operation, and ensuring the safe and stable operation of the hydropower system.

[0009] This invention provides a test system for the start-up and shutdown process of a hydro-generator unit without hydroelectric power generation, the specific technical solution of which is as follows: The system includes a simulation test model and a test platform, wherein the simulation test model is connected to the test platform; The simulation test model includes a basic parameter layer, a logical rule layer, and a historical operating condition layer; The basic parameter layer stores the core parameters of the mechanical system and the core parameters of the electrical system; The logic rule layer includes a logic function library, which includes single-system control logic and process logic broken down into standardized steps according to operation type. Each standardized step is associated with triggering conditions, execution actions, and feedback parameters. The historical operating condition layer includes an operating condition sample library, which includes complete time-series data of normal and abnormal operating conditions. The test platform includes a state recording module, a condition enforcement module, a data import module, and an anomaly diagnosis module; The status recording module is connected to the basic parameter layer data to obtain the status of each system before the experiment and generate standardized documents; The condition enforcement module forcibly sets and records the enforcement operation for any unmet power-on conditions based on the logical rule layer. The data import module is connected to the historical operating condition layer; The anomaly diagnosis module is connected to the logical rule layer and the historical operating condition layer. It uses machine learning algorithms to identify anomalies during the test process, locate the root cause of the problem, and generate an analysis report.

[0010] Furthermore, the core parameters of the mechanical system are stored as key set values ​​based on system classification, while the core parameters of the electrical system are stored according to equipment type.

[0011] Furthermore, the core mechanical system parameters in the basic parameter layer include: the rated speed of the speed regulation system, the guide vane opening / closing time and PID adjustment parameters; the action pressure threshold, emergency shutdown response time and full opening / full closing stroke of the cylindrical valve; the air storage tank pressure range, brake air pressure setpoint and air replenishment trigger pressure of the air system; and the technical water supply pressure, bearing cooling flow rate and oil temperature alarm threshold of the auxiliary facilities.

[0012] Furthermore, the core electrical system parameters in the basic parameter layer include: the no-load excitation voltage, strong excitation multiple, and demagnetization time constant of the excitation system; the rated voltage, rated current, and power factor of the generator; and the overspeed protection threshold and demagnetization protection action criteria of the protection settings.

[0013] Furthermore, the process logic of the logic rule layer includes a normal startup process and an emergency shutdown process; The triggering condition for the normal startup process is that the auxiliary system pressure or liquid level reaches the standard, the execution action is the excitation system pressure build-up, and the feedback parameter is the excitation voltage rise rate. The emergency shutdown procedure is triggered when the rotational speed is not less than 140% of the rated value or the cylinder valve slides down by not less than 0.5m. The action is for the speed governor to urgently close the guide vane and the cylinder valve to lower the gate. The feedback parameters are the guide vane full closing time and the cylinder valve to lower the gate signal.

[0014] Furthermore, the anomaly diagnosis module is equipped with a machine learning algorithm engine and a parameter correlation analysis model engine.

[0015] This invention also provides a test method for the start-up and shutdown process of a hydro-generator unit without water turbines, characterized in that, based on the above-mentioned test system for the start-up and shutdown process of a hydro-generator unit without water turbines, the method includes: S1: Import the start-up and shutdown times and analog quantity data of the test unit within the set period through the data import module; S2: Record the status of each system of the unit and the status of the soft pressure plate before the test through the status recording module; S3: Through the condition enforcement module, force the conditions that are not met when starting / stopping the unit to be met, and record them; S4: Execute the corresponding start / stop operation; S5: Acquire test data and identify anomalies and locate the root cause of problems through the anomaly diagnosis module; S6: Based on the results of step S5, perform defect elimination and debugging; S7: Remove the forced setting in step S3 and verify it; S8: Comparison of unit status before and after the test.

[0016] Furthermore, after step S8, step S9 is also included: generating and outputting a test report containing test data, abnormal signals, system diagnosis and defect handling.

[0017] Furthermore, the standardized documents and test reports are in CSV or Excel format.

[0018] The beneficial effects of this invention are as follows: 1. This invention replaces the traditional manual experience-based waterless commissioning with a simulation test model, real-time monitoring, and intelligent diagnosis. During the waterless stage, the start-up and shutdown procedures of the mechanical, electrical, and control systems are incorporated into the same standardized test framework, exposing design, installation, or logic defects in one go, reducing the number of shutdowns for rectification after water filling and the risk of accidents. After the test process is completed, the test data, abnormal conclusions, and handling suggestions are generated into a CSV / Excel report, which greatly shortens the commissioning cycle. The modular architecture of the system can be quickly ported to units of different capacities and from different manufacturers, achieving out-of-the-box commissioning.

[0019] 2. The basic parameter layer stores key fixed values ​​in a dual-dimensional classification of system and equipment. The logic rule layer breaks down complex processes into standardized steps of triggering, execution, and feedback. The historical operating condition layer injects real fault timing samples. The three-layer coupling of the model makes the simulation accuracy highly consistent with the actual operating conditions, eliminating misjudgments or omissions caused by model distortion.

[0020] 3. The condition enforcement module enforces unmet conditions such as oil pressure, air pressure, and liquid level at the logic level to ensure the continuous operation of the start-up and shutdown process. At the same time, it records the personnel, time, and parameter values ​​for enforcement, which not only supports complete testing but also meets the needs of post-event auditing and fault inversion, avoiding safety blind spots. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the method flow of the present invention. Detailed Implementation

[0022] The technical solutions in the embodiments of the present invention are clearly and completely described in the following description. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] In the description of the embodiments of the present invention, it should be noted that the indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is conventionally placed during use, or the orientation or positional relationship in which those skilled in the art conventionally understand it during use. This is only for the convenience of describing the present invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of the present invention. Furthermore, the terms "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0024] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0025] Example 1 Embodiment 1 of the present invention discloses a test system for the start-up and shutdown process of a hydro-generator unit without water turbines, as detailed below: The system includes a simulation test model and a test platform, wherein the simulation test model is connected to the test platform; Specifically, the simulation test model is embedded in the power plant monitoring system to form a test platform.

[0026] The simulation test model includes a basic parameter layer (static database), a logical rule layer (dynamic control engine), and a historical operating condition layer.

[0027] The basic parameter layer stores the core parameters of the mechanical system and the core parameters of the electrical system; In a preferred embodiment, the core parameters of the mechanical system are based on key fixed values ​​stored in the system classification. Specifically, the core parameters of the mechanical system in the basic parameter layer include: Rated speed of the speed control system (e.g., 300 r / min), guide vane opening / closing time (e.g., 10 s / 8 s), PID control parameters (proportional coefficient Kp, integral time Ti, etc.). Operating pressure threshold of cylindrical valve (e.g., 4.5MPa), emergency shut-off response time (≤3s), and full open / full close stroke (e.g., 1.2m); The air system's air tank pressure range (0.6-0.8MPa), brake air pressure setpoint (0.4MPa), and air replenishment trigger pressure (0.55MPa); Technical water supply pressure (0.2-0.3MPa), bearing cooling flow rate (e.g., 50m³ / h), and oil temperature alarm threshold (≤50°C) for auxiliary facilities.

[0028] The core parameters of the electrical system are stored according to equipment type; Specifically, the core electrical system parameters in the basic parameter layer include: The no-load excitation voltage of the excitation system (e.g., 120V), the excitation multiple (2 times), and the demagnetization time constant (≤0.2s). The generator's rated voltage (e.g., 10.5kV), rated current (e.g., 1500A), and power factor (0.85 lagging). Overspeed protection threshold (115% of rated speed) and loss of excitation protection action criteria (reactive reverse + voltage drop).

[0029] The logic rule layer includes a logic function library, which is constructed based on the control logic and process logic of each system. It includes single-system control logic and process logic that is broken down into standardized steps according to operation type. Each standardized step is associated with triggering conditions, execution actions, and feedback parameters.

[0030] As a preferred embodiment, the single-system control logic of the logic rule layer is specifically as follows: Technical water supply system: main and standby pump switching logic (the standby pump automatically starts when the water supply pressure is <0.18MPa), water outage protection delay (5s triggers shutdown). Speed ​​control system: The linkage curve between guide vane opening and speed when the machine is started (e.g., when the speed rises to 90% of the rated value, the guide vane opening remains at 30%).

[0031] In a preferred embodiment, the process logic of the logic rule layer includes a normal startup process and an emergency shutdown process; The triggering condition for the normal startup process is that the auxiliary system pressure or liquid level reaches the standard, the execution action is the excitation system pressure build-up, and the feedback parameter is the excitation voltage rise rate. The emergency shutdown procedure is triggered when the rotational speed is not less than 140% of the rated value or the cylinder valve slides down by not less than 0.5m. The action is for the speed governor to urgently close the guide vane and the cylinder valve to lower the gate. The feedback parameters are the guide vane full closing time and the cylinder valve to lower the gate signal.

[0032] The historical operating condition layer includes an operating condition sample library, which includes complete time-series data of normal and abnormal operating conditions. Specifically, under normal operating conditions: start-up and shutdown curves (such as the trend of guide vane opening over time) under different loads (50%, 80%, 100% of rated load), and fluctuation range of key parameters (such as bearing temperature 30-40°C). Abnormal operating conditions: Complete time-series data of historical fault cases (such as "water supply interruption leading to shutdown") (pressure, temperature, and action signals from 30 seconds before the fault to 60 seconds after the shutdown).

[0033] The test platform includes a state recording module, a condition enforcement module, a data import module, and an anomaly diagnosis module.

[0034] The status recording module is connected to the basic parameter layer data to obtain the status of each system before the test (such as the soft pressure plate deployment and deactivation status, gas system pressure value), and generate standardized documents; Specifically, the standardized document is in CSV or Excel format.

[0035] The condition enforcement module, based on the logical rule layer, forces the setting of unmet power-on conditions and records the enforcement operation (operator, time, parameter value).

[0036] The data import module is connected to the historical operating condition layer and imports start-up and shutdown events and analog data (such as speed and excitation current timing curves) within a set period.

[0037] The anomaly diagnosis module is connected to the logical rule layer and the historical operating condition layer. It uses machine learning algorithms (such as decision tree, LSTM) to identify anomalies in the test process (such as guide vane closing time exceeding the standard value of 2s) and locate the root cause of the problem (such as low governor oil pressure) and generate an analysis report.

[0038] Specifically, the anomaly diagnosis module is equipped with a machine learning algorithm engine and a parameter correlation analysis model engine.

[0039] Example 2 Embodiment 2 of the present invention discloses a test method for the start-up and shutdown process of a hydro-generator unit without water, based on Embodiment 1 above. Figure 1 As shown, the specific steps are as follows: S1: Import the start-up and shutdown times and analog quantity data of the test unit within the set period through the data import module; S2: Record the status of each system of the unit and the status of the soft pressure plate before the test through the status recording module; S3: Through the condition enforcement module, force the conditions that are not met when starting / stopping the unit to be met, and record them; S4: Execute the corresponding start / stop operation; S5: Acquire experimental data, use machine learning algorithms to analyze parameter change trends, and identify abnormal patterns (such as abnormal temperature and abnormal liquid level); based on the operating mechanism model of the hydro-generator unit, construct a parameter correlation analysis model to locate the root cause of the problem (the location and probability of abnormal temperature points). S6: Based on the results of step S5, perform defect elimination and debugging; S7: Remove the forced setting in step S3 and verify it; S8: Comparison of unit status before and after the test.

[0040] S9: Generate and output a test report containing test data, abnormal signals, system diagnostics, and defect handling; Specifically, the test report should be in CSV or Excel format.

[0041] This invention is not limited to the specific embodiments described above. The invention extends to any new feature or combination disclosed in this specification, as well as any new method or process step or combination disclosed herein.

Claims

1. A water turbine generator unit water-free mechanical and electrical joint debugging start-stop process test system, characterized in that, The simulation test model is connected with the test platform; The simulation test model comprises a basic parameter layer, a logic rule layer and a historical working condition layer; The basic parameter layer stores mechanical system core parameters and electrical system core parameters; The logic rule layer comprises a logic function library, which comprises single-system control logic and process logic decomposed into standardized steps according to operation types, and each standardized step is associated with a trigger condition, an execution action and a feedback parameter; The historical working condition layer comprises a working condition sample library, which comprises complete time sequence data of normal working conditions and abnormal working conditions; The test platform comprises a state recording module, a condition forcing module, a data importing module and an abnormality diagnosis module; The state recording module is connected with the basic parameter layer to obtain the states of each system before the test and generate a standardized document; The condition forcing module forcibly sets the conditions that are not met and records the forced operations based on the logic rule layer; The data importing module is connected with the historical working condition layer; The abnormality diagnosis module is connected with the logic rule layer and the historical working condition layer, and identifies abnormalities in the test process and locates the problem sources to generate an analysis report through a machine learning algorithm.

2. The test system for the open and shutdown process of the water turbine generator unit without water electromechanical joint debugging according to claim 1, characterized in that, The mechanical system core parameters store key fixed values based on system classification, and the electrical system core parameters are stored according to equipment types.

3. The test system for the open and shutdown process of the water turbine generator unit without water electromechanical joint debugging according to claim 2, characterized in that, The mechanical system core parameters in the basic parameter layer comprise rated rotating speed, guide vane opening / closing time and PID adjustment parameters of a speed regulation system, action pressure threshold, emergency shutdown response time and full opening / full closing stroke of a cylinder valve, gas tank pressure range, brake gas pressure fixed value and air supplement trigger pressure of a gas system, and technical water supply pressure, bearing cooling flow and oil temperature alarm threshold of auxiliary facilities.

4. The test system for open and shutdown process of hydroelectric generating unit without water according to claim 2, characterized in that, The electrical system core parameters in the basic parameter layer comprise no-load excitation voltage, forced excitation multiple and de-excitation time constant of an excitation system, rated voltage, rated current and power factor of a generator, and overspeed protection threshold and loss-of-field protection action criterion of protection fixed values.

5. The test system for open and shutdown process of hydroelectric generating unit without water according to claim 1, characterized in that, The process logic of the logic rule layer comprises a normal startup process and an emergency shutdown process; The trigger condition of the normal startup process is that the pressure or liquid level of an auxiliary system meets the standard, the execution action is to build pressure of an excitation system, and the feedback parameter is the rising rate of excitation voltage; The trigger condition of the emergency shutdown process is that the rotating speed is not less than 140% of the rated value or the cylinder valve slides down by not less than 0.5 m, the execution action is to close the guide vane and drop the cylinder valve of a speed regulator, and the feedback parameter is the full-closing time of the guide vane and the drop-to-position signal of the cylinder valve.

6. The test system for open and shutdown process of hydroelectric generating unit without water according to claim 1, characterized in that, The abnormality diagnosis module is deployed with a machine learning algorithm engine and a parameter correlation analysis model engine.

7. A method for testing the open and shutdown process of a water-turbine generator unit in a water-free mechanical and electrical commissioning process, characterized in that, The water-turbine-generator-unit water-free mechanical and electrical joint startup / shutdown process test system and method according to any one of claims 1-6 comprise: S1: importing, through the data importing module, the startup / shutdown time and analog quantity data of a test unit within a set period; S2: recording, through the state recording module, the states of each system of the unit and the state of a soft pressure plate before the test; S3: forcibly setting, through the condition forcing module, the conditions that are not met for the startup / shutdown of the unit to be met, and recording. S4: Perform corresponding start / stop operation; S5: Obtain test data, and perform abnormality identification and problem root location through an abnormality diagnosis module; S6: Eliminate defects and perform debugging according to the result of step S5; S7: Release the forced setting in step S3, and perform checking; S8: Compare the state of the unit before and after the test.

8. The method according to claim 7, wherein the method is characterized in that, After step S8, S9: Generate a test report containing test data, abnormality signals, system diagnosis and defect processing, and output the test report.

9. The method of claim 7, wherein the method further comprises: The format of the standardized document and the test report is CSV or Excel.

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