Modular architecture and configuration method for upgrading a turbine TSI system

Abstract

This invention discloses a modular architecture and configuration method for upgrading and retrofitting a steam turbine TSI system. The architecture includes a standardized frame unit, a set of functional modules, an online hot-swappable structure, redundant power supply configuration, a status indication and diagnostic unit, and a host computer configuration interface. The old frame and modules are removed, and the standardized frame unit is installed in its original position. Slots for each functional module are reserved within the frame. The power supply module, monitoring and protection module, monitoring I / O module, relay module, and overspeed monitoring module are sequentially inserted into their corresponding slots in the frame. This invention solves problems such as inconsistent interfaces, low module standardization, complex maintenance, and lack of online diagnostics in existing TSI system upgrades, achieving efficient, safe, and scalable upgrades of the TSI system.

Description

Technical Field

[0001] This invention relates to the field of turbine monitoring instrument (TSI) technology in thermal power plants, specifically to a modular architecture and configuration method for upgrading and retrofitting a turbine TSI system. Background Technology

[0002] Turbine monitoring instrumentation (TSI) systems are critical equipment for the safe operation of thermal power units. They are used to continuously monitor important mechanical operating parameters of the turbine during startup, operation, and shutdown, such as shaft vibration, bearing vibration, axial displacement, differential expansion, speed, and eccentricity. Currently, many early-stage units in China use imported TSI systems (such as the VM600 system from Vibro-Meter of Switzerland), which have been in operation for over 10 years and are facing problems such as equipment aging, discontinuation of spare parts, and lack of inventory.

[0003] The main technical problems in the upgrade and transformation of the existing TSI system are as follows: (1) The interface between the old system and the new system is not uniform, and the transformation involves a large number of hard wiring changes, resulting in a long construction period; (2) Each monitoring module lacks standardized design, and the size and specifications of different functional modules are different. There are many types of spare parts, resulting in high maintenance costs; (3) The addressing of the module is affected by the position of the slot in the cabinet. After replacing the module, it needs to be reconfigured, which increases the complexity of maintenance; (4) The system lacks complete online diagnostic and status indication functions, making fault diagnosis difficult. Summary of the Invention

[0004] This invention provides a modular architecture and configuration method for upgrading and transforming a steam turbine TSI system, aiming to solve problems such as inconsistent interfaces, low module standardization, complex maintenance, and lack of online diagnostics in the upgrading and transformation of existing TSI systems, and to achieve efficient, safe, and scalable upgrades of the TSI system.

[0005] A modular architecture for upgrading and retrofitting a steam turbine TSI system includes: Standardized chassis unit: adopts ABE040 / 204-040-100-016 type monitor frame (or equivalent standardized chassis), with a unified bus board inside the chassis for power distribution and data communication between modules.

[0006] The functional module set includes, but is not limited to: a power supply module, which adopts a redundant parallel configuration to power the entire system; a monitoring and protection module, used to collect and process monitoring signals such as shaft vibration, bearing vibration, axial displacement, and differential expansion; a monitoring I / O module, used in conjunction with the monitoring and protection module to complete signal input and output; a relay module, used to output alarm and shutdown signals; and an overspeed monitoring module, used for speed measurement and overspeed protection.

[0007] Standardized modular design: All modules adopt solid-state circuits, standardization, modularization, and plug-in structure; the types and sizes of modules are uniform, and modules of the same type are completely interchangeable, reducing the types and costs of spare parts; the addressing of modules is not affected by the slot position in the rack, and they can perform their functions in any slot position; all modules are equipped with automatic identification and LED diagnostic indication functions.

[0008] Online hot-swap structure: All modules support online and hot-swap replacement without damaging or affecting the normal operation of other modules; the module insertion and removal are equipped with guide rails and interlocking mechanisms.

[0009] Redundant power supply configuration: The system's operating power supply adopts a parallel redundant configuration, which automatically switches when any power module fails, without affecting the normal operation of the system.

[0010] Status indication and diagnostic unit: The operating status of all monitor modules and I / O channels is output to an external monitoring system (such as ETS) via dry contacts; when any module fails, the external monitoring system obtains an indication through changes in contact status.

[0011] Host computer configuration interface: The system configures application software and supporting hardware that communicate directly with the PC, supports offline or online configuration and testing of application software, and has the function of monitoring the unit's real-time and historical TSI data and fault query through the PC.

[0012] A method for upgrading and configuring a TSI system based on the above modular architecture includes the following steps: Step S1: Remove the old frame and modules, and install the standardized frame unit in the original position, with slots reserved inside the frame for each functional module; Step S2: According to functional requirements, insert the power supply module, monitoring and protection module, monitoring I / O module, relay module, and overspeed monitoring module into the corresponding slots in the chassis in sequence; the addressing of each module is independent of the slot position and will be automatically recognized after insertion; Step S3: Configure parameters and functions for each monitoring and protection module using the host computer configuration software, including parameters such as the range, alarm value, shutdown value, and delay time for each channel; Step S4: Perform power circuit check, power on the device and restore the software to confirm that each module is working properly; Step S5: Perform signal loop testing to verify that the signals from each sensor are correctly transmitted to the corresponding module; Step S6: Perform TSI alarm and protection transmission tests to verify that the alarm and shutdown values ​​are set correctly; Step S7: Conduct joint debugging tests between TSI and external systems such as DEH, ETS, and DCS, and achieve data sharing through standard data communication interfaces (including configuration) and communication software; Step S8: After the system is put into operation, the operating status of each module is monitored in real time through the host computer. When any module fails, a fault indication is sent to the ETS system through the change of dry contact status.

[0013] This invention achieves the following beneficial effects: It employs a parallel redundant configuration with automatic switching between primary and backup modules, with a switching time ≤20ms, ensuring the TSI system is unaffected by power outages. Real-time sampling of output voltage, current, temperature, and other parameters, along with reporting operating status via a communication interface, allows for early prediction of power module failures. Power modules support hot-swapping, enabling online replacement of faulty modules while the system is running without downtime. Protection circuits provide rapid protection against overvoltage, undervoltage, and overcurrent anomalies (response time ≤10ms), preventing fault escalation. Any power module failure does not affect normal unit operation, meeting the requirement that TSI system hardware failures should not cause unit tripping. Intelligent load balancing and power consumption management reduce the continuous high-load operation time of individual power modules, extending the overall lifespan of the equipment. Detailed Implementation

[0014] A modular architecture for upgrading and retrofitting a steam turbine TSI system includes: Standardized chassis unit: adopts ABE040 / 204-040-100-016 type monitor frame (or equivalent standardized chassis), with a unified bus board inside the chassis for power distribution and data communication between modules.

[0015] A collection of functional modules, including but not limited to: The power supply module (such as RPS6U / 200-582-500-121) adopts a redundant parallel configuration to supply power to the entire system; Monitoring and protection modules (such as MPC4-MK2 / 601-040-A3) are used to collect and process monitoring signals such as shaft vibration, bearing vibration, axial displacement, and differential expansion. Monitoring I / O modules (such as IOC4T-MK2 / 600-042) are used in conjunction with monitoring and protection modules to complete signal input and output. Relay modules (such as RLC16-Mk2 / 600-044) are used to output alarm and shutdown signals; Overspeed monitoring modules (such as T77530-10) are used for speed measurement and overspeed protection.

[0016] Module-based standardized design: All modules adopt solid-state circuits, standardization, modularization, and plug-in structure; The types and sizes of modules are standardized, and modules of the same type are completely interchangeable, reducing the types and costs of spare parts; The module's addressing is not affected by its slot position within the rack, and it can perform its function from any slot position. All modules are equipped with automatic identification and LED diagnostic indicators.

[0017] Online hot-swap structure: All modules support online and hot-swap replacement without damaging or affecting the normal operation of other modules; the module insertion and removal are equipped with guide rails and interlocking mechanisms.

[0018] Redundant power supply configuration: The system's operating power supply adopts a parallel redundant configuration, which automatically switches when any power module fails, without affecting the normal operation of the system.

[0019] Status indication and diagnostic unit: The operating status of all monitor modules and I / O channels is output to an external monitoring system (such as ETS) via dry contacts; when any module fails, the external monitoring system obtains an indication through changes in contact status.

[0020] Host computer configuration interface: The system configures application software and supporting hardware that communicate directly with the PC, supports offline or online configuration and testing of application software, and has the function of monitoring the unit's real-time and historical TSI data and fault query through the PC.

[0021] A method for upgrading and configuring a TSI system based on the above modular architecture includes the following steps: Step S1: Remove the old frame and modules, and install the standardized frame unit in the original position, with slots reserved inside the frame for each functional module; Step S2: According to functional requirements, insert the power supply module, monitoring and protection module, monitoring I / O module, relay module, and overspeed monitoring module into the corresponding slots in the chassis in sequence; the addressing of each module is independent of the slot position and will be automatically recognized after insertion; Step S3: Configure parameters and functions for each monitoring and protection module using host computer configuration software (such as VIBROSIGHT / 608-001-000-SSS-A03-B64-C0-D3), including parameters such as the range, alarm value, shutdown value, and delay time of each channel. Step S4: Perform power circuit check, power on the device and restore the software to confirm that each module is working properly; Step S5: Perform signal loop testing to verify that the signals from each sensor are correctly transmitted to the corresponding module; Step S6: Perform TSI alarm and protection transmission tests to verify that the alarm and shutdown values ​​are set correctly; Step S7: Conduct joint debugging tests between TSI and external systems such as DEH, ETS, and DCS, and achieve data sharing through standard data communication interfaces (including configuration) and communication software; Step S8: After the system is put into operation, the operating status of each module is monitored in real time through the host computer. When any module fails, a fault indication is sent to the ETS system through the change of dry contact status.

Claims

1. A modular architecture for upgrading and retrofitting a steam turbine TSI system, comprising a standardized frame unit, a set of functional modules, an online hot-swappable structure, redundant power supply configuration, a status indication and diagnostic unit, and a host computer configuration interface, characterized in that: The standardized chassis unit adopts the ABE040 / 204-040-100-016 monitor frame, with a unified busbar inside for power distribution and data communication between modules. All modules use solid-state circuits, standardization, modularity, and plug-in structure. The types and sizes of modules are uniform, and modules of the same type are completely interchangeable. The addressing of modules is not affected by the slot position in the rack, and they can perform their functions in any slot position. All modules have automatic identification and LED diagnostic indication functions. All modules support online and hot-swappable replacement, and the module plug-in / plug-out is equipped with guide rails and interlocking mechanisms.

2. The modular architecture for upgrading and retrofitting the steam turbine TSI system according to claim 1, characterized in that, The functional module set includes: a power supply module, which adopts a redundant parallel configuration to power the entire system; a monitoring and protection module, which is used to collect and process monitoring signals such as shaft vibration, bearing vibration, axial displacement, and differential expansion; a monitoring I / O module, which is used in conjunction with the monitoring and protection module to complete signal input and output; a relay module, which is used to output alarm and shutdown signals; and an overspeed monitoring module, which is used for speed measurement and overspeed protection.

3. The modular architecture for upgrading and retrofitting the steam turbine TSI system according to claim 2, characterized in that, Redundant power supply configuration refers to the system's operating power supply adopting a parallel redundant configuration, which automatically switches when any power module fails, without affecting the normal operation of the system.

4. The modular architecture for upgrading and retrofitting the steam turbine TSI system according to claim 3, characterized in that, The status indication and diagnostic unit includes a monitor module. The operating status of all monitor modules and I / O channels is output to the external monitoring system via dry contacts. When any module fails, the external monitoring system obtains an indication through changes in the contact status.

5. The modular architecture for upgrading and retrofitting the steam turbine TSI system according to claims 1-4, characterized in that, It has a host computer configuration interface: the system is configured with application software and supporting hardware that communicate directly with a PC, supports offline or online configuration and testing of application software, and has the function of monitoring the unit's TSI real-time and historical data and querying faults through a PC.

6. A configuration method for upgrading and transforming a TSI system based on the above modular architecture, comprising the following steps: Step S1: Remove the old frame and modules, and install the standardized frame unit in the original position, with slots reserved inside the frame for each functional module; Step S2: According to functional requirements, insert the power supply module, monitoring and protection module, monitoring I / O module, relay module, and overspeed monitoring module into the corresponding slots in the chassis in sequence; the addressing of each module is independent of the slot position and will be automatically recognized after insertion; Step S3: Configure parameters and functions for each monitoring and protection module using the host computer configuration software, including parameters such as the range, alarm value, shutdown value, and delay time for each channel; Step S4: Perform power circuit check, power on the device and restore the software to confirm that each module is working properly; Step S5: Perform signal loop testing to verify that the signals from each sensor are correctly transmitted to the corresponding module; Step S6: Perform TSI alarm and protection transmission tests to verify that the alarm and shutdown values ​​are set correctly; Step S7: Conduct joint debugging tests between TSI and external systems such as DEH, ETS, and DCS, and achieve data sharing through standard data communication interfaces and communication software; Step S8: After the system is put into operation, the operating status of each module is monitored in real time through the host computer. When any module fails, a fault indication is sent to the ETS system through the change of dry contact status.