Condition monitoring and failure early-warning system and method for boiler water-cooled wall of power station

Abstract

A condition monitoring and failure early-warning system for a boiler water-cooled wall of a power station, comprising an on-site collection system, a superordinate computer system, and a network communication system. The on-site collection system comprises a plurality of measurement devices and data acquisition devices arranged on the boiler water-cooled wall; the data acquisition devices are connected to the superordinate computer system by means of the network communication system. The superordinate computer system comprises a computer simulation system and a failure early-warning system. The computer simulation system obtains a digital twin model comprising temperature field and stress field distributions of the entire boiler water-cooled wall. On the basis of on-site measurement point data, the failure early-warning system calculates simulation data to perform safety evaluation and provide predictive alarms; and online safety evaluation and intelligent failure early-warning are performed on the boiler water-cooled wall, thereby greatly improving the early warning accuracy.

Description

A power station boiler water wall state monitoring and failure early warning system and method TECHNICAL FIELD

[0001] The present application belongs to the field of in-service power station equipment state monitoring and safety evaluation, and relates to a power station boiler water wall state monitoring and failure early warning system and method. BACKGROUND

[0002] In recent years, with the needs of new power system construction, the role of thermal power generating units in power supply is also changing. From the national policy level, it is encouraged to carry out flexible transformation of thermal power generating units and participate in deep peak regulation. However, frequent start-stop, long-term low-load operation and rapid load change of deep peak regulation will have a great impact on the safe operation of important equipment of the unit, especially the boiler water wall, causing frequent accidents such as boiler water wall pipe explosion, cracking and deformation in recent years, which also poses a great threat to the safety of operating personnel. At present, the treatment scheme for boiler water wall accidents mainly focuses on increasing personnel inspection during operation and strengthening metal supervision and repair and maintenance during maintenance, but lacks online monitoring of the health state of the boiler water wall, which cannot discover the existing safety hazards in advance and evaluate and intelligently early warn in real time. Based on this, it is very necessary to develop a power station boiler water wall state monitoring and failure early warning system by measuring the basic operation state data of the boiler water wall and realizing data-physical fusion.

[0003] SUMMARY

[0004] The purpose of the present application is to overcome the shortcomings of the prior art, and to provide a power station boiler water wall state monitoring and failure early warning system and method based on data-physical fusion driving. The system and method can monitor the state of the deep peak regulation power station boiler water wall in real time, and evaluate the safety online and intelligently early warn the failure.

[0005] A power station boiler water wall state monitoring and failure early warning system, comprising a field acquisition system, an upper computer system and a network communication system, characterized in that,

[0006] The field acquisition system comprises a plurality of measuring devices and a data acquisition device arranged on the boiler water wall;

[0007] The plurality of measuring devices comprises a plurality of temperature measuring devices (21, 22-2n), a plurality of strain measuring devices (31, 32-3n), a plurality of displacement measuring devices (41, 42-4n) and a plurality of vibration measuring devices (51, 52-5n);

[0008] The data acquisition device is connected to the upper computer system through the network communication system;

[0009] The host computer system comprises a computer simulation system and a failure early warning system.

[0010] The computer simulation system (9) is used for establishing a physical model of the boiler water wall according to original input data and performing simulation calculation on a temperature field and a stress field to obtain a preliminary temperature field distribution and a preliminary stress field distribution, and then fusing the collected temperature, displacement, vibration and stress data by using a transfer learning model to obtain a digital twin model including the temperature field distribution and the stress field distribution of the entire boiler water wall.

[0011] The failure early warning system is used for performing over-limit alarm based on the field measurement point data and the computer simulation real-time data, and performing safety evaluation and prediction alarm based on the field measurement point data and the computer simulation real-time data.

[0012] A power station boiler water wall state monitoring and failure early warning method has the characteristics that,

[0013] The method comprises the following steps:

[0014] Step 1: input the original design parameters of the boiler water wall (1) into the computer simulation system (9) to establish a finite element stress calculation model of the boiler water wall (1) in step 3.

[0015] Step 2: analyze and determine the temperature sensitive area, the deformation sensitive area and the vibration sensitive area of the boiler water wall.

[0016] According to the set rules, a plurality of temperature measuring devices (21, 22-2n) are arranged at the parts of the boiler water wall (1) including the temperature sensitive area, a plurality of displacement measuring devices (41, 42-4n) are arranged at the parts of the boiler water wall (1) including the deformation sensitive area, and a plurality of vibration measuring devices (51, 52-5n) are arranged at the parts of the boiler water wall (1) including the vibration sensitive area.

[0017] Step 3: obtain the digital twin model of the temperature field distribution and the stress field distribution of the entire boiler water wall based on the finite element calculation and the transfer learning model.

[0018] Step 4: perform over-limit alarm and prediction alarm based on the field measurement point data and the computer simulation data.

[0019] The method has the following beneficial effects:

[0020] Compared with the prior art, the power station boiler water wall state monitoring and failure early warning system and method based on data-physical fusion driving is designed, wherein based on finite element calculation and migration learning model, a digital twin model of temperature field distribution and stress field distribution of the whole boiler water wall is obtained; and further based on field measurement point data and digital twin model simulation data, over-limit alarm and safety evaluation prediction are carried out; the safety of the boiler water wall is evaluated and intelligently failure is early warned, so that the early warning accuracy is greatly improved. BRIEF DESCRIPTION OF DRAWINGS

[0021] Fig. 1 is a structural schematic diagram of the present application;

[0022] Fig. 2 is a schematic diagram of the water wall in A-A direction;

[0023] Fig. 3 is a method step diagram of the present application;

[0024] Fig. 4 is a processing flow diagram of the present application;

[0025] In the figure: boiler water wall (1), temperature measuring device (21, 22~2n), strain measuring device (31, 32~3n), displacement measuring device (41, 42~4n), vibration measuring device (51, 52~5n), data acquisition device (61, 62~6n), switch system (7), control operation system (8), computer simulation system (9), failure early warning system (10), water wall tube (11), fin (12), power supply system (13), power supply line (14). DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0027] As shown in Fig. 1, a power station boiler water wall state monitoring and failure early warning system includes a field acquisition system, an upper computer system and a network communication system.

[0028] The field acquisition system includes various measuring devices and data acquisition devices arranged on the boiler water wall.

[0029] The boiler water wall (1) to be monitored is composed of water wall tube (11) and fin (12);

[0030] The plurality of measuring devices include a plurality of temperature measuring devices (21, 22-2n), a plurality of strain measuring devices (31, 32-3n), a plurality of displacement measuring devices (41, 42-4n), and a plurality of vibration measuring devices (51, 52-5n);

[0031] The plurality of data acquisition devices (61, 62-6n) are connected to the plurality of measuring devices through data lines.

[0032] In order to facilitate signal detection on the entire structure surface of the water wall, a plurality of data acquisition devices (61, 62-6n) are distributedly arranged, wherein each data acquisition device is connected to one or more of the temperature measuring device, the strain measuring device, the displacement measuring device, and the vibration measuring device through a data line, that is, the entire structure surface of the water wall is first divided into a plurality of array monitoring regions, and one data acquisition device is arranged in each monitoring region. The data acquisition device is connected to one or more of the temperature measuring device, the strain measuring device, the displacement measuring device, and the vibration measuring device according to the arrangement mode of the measuring points, and the connected measuring devices can collect temperature, strain, displacement, and vibration data in the corresponding monitoring region in real time. The data acquired by each data acquisition device is transmitted to a network communication system through a network, and a wired or wireless network communication mode can be used. A switch is arranged in the network communication system.

[0033] When a wired network is used, the plurality of data acquisition devices can be connected to a field bus and exchange data with the switch connected to the field bus; when a wireless network is used, the plurality of data acquisition devices can be connected to a ZigBee or WIFI network and perform wireless network communication with the switch.

[0034] The switch is further connected to an upper computer system.

[0035] In addition, a power supply system is further provided to supply power to the field acquisition system, the upper computer system, and the network communication system.

[0036] When the system is arranged,

[0037] The plurality of temperature measuring devices (21, 22-2n), the plurality of strain measuring devices (31, 32-3n), the plurality of displacement measuring devices (41, 42-4n), and the plurality of vibration measuring devices (51, 52-5n) are directly fixed or connected to the water wall pipe (11) or the fin (12) to be monitored through a positioning device;

[0038] The plurality of temperature measuring devices (21, 22-2n) are arranged in the temperature sensitive region of the water wall pipe (11) or the fin (12) of the boiler water wall (1).

[0039] A plurality of strain measurement devices (31, 32~3n) are arranged in the stress failure sensitive area of the water wall tube (11) or fin (12) of the boiler water wall (1);

[0040] A plurality of displacement measurement devices (41, 42~4n) are arranged in the deformation sensitive area of the water wall tube (11) or fin (12) of the boiler water wall (1);

[0041] A plurality of vibration measurement devices (51, 52~5n) are arranged in the vibration sensitive area of the water wall tube (11) or fin (12) of the boiler water wall (1);

[0042] The temperature measurement point device (21, 22~2n), strain measurement device (31, 32~3n), displacement measurement device (41, 42~4n), and vibration measurement device (51, 52~5n) are arranged on the water wall tube (11) or fin (12) to be monitored according to the set rules, and the other end is connected to a plurality of distributed data acquisition devices (61, 62~6n) through data lines according to the set rules, and then connected to the upper computer system through the switch system (7);

[0043] The upper computer system includes a control operation system, a computer simulation system, and a failure warning system.

[0044] The control operation system (8) is used to provide human-computer interaction, data acquisition, data storage, statistical analysis, system setting, and other functions.

[0045] The computer simulation system (9) is used to establish a boiler water wall physical model according to the original input data and perform temperature field and stress field simulation calculation to obtain the preliminary temperature field distribution and stress field distribution, and then use the transfer learning model to fuse the collected temperature, displacement, vibration, stress, and other data to obtain a digital twin model including the temperature field distribution and stress field distribution of the entire boiler water wall;

[0046] The failure warning system is used to perform over-limit alarm based on the field measurement point data and the calculation simulation real-time data, and can also perform safety evaluation based on the field measurement point data and the calculation simulation real-time data to perform prediction alarm.

[0047] As shown in FIGS. 1 and 2, a power station boiler water wall state monitoring and failure warning method, wherein the corresponding boiler water wall digital twin model is calculated, including the following steps:

[0048] Step 1, input the original design parameters of the boiler water wall (1) into the computer simulation system (9) to establish the finite element stress calculation model of the boiler water wall (1) in step 3;

[0049] Step 2, analyze to determine the temperature sensitive area, deformation sensitive area and vibration sensitive area of the boiler water wall;

[0050] According to the set rules, a plurality of temperature measuring devices (21, 22~2n) are arranged at the parts of the boiler water wall (1) including the temperature sensitive area, a plurality of displacement measuring devices (41, 42~4n) are arranged at the parts of the boiler water wall (1) including the deformation sensitive area, and a plurality of vibration measuring devices (51, 52~5n) are arranged at the parts of the boiler water wall (1) including the vibration sensitive area;

[0051] Step 3, obtain the digital twin model of the temperature field distribution and stress field distribution of the entire boiler water wall;

[0052] 3-1, establish a finite element stress calculation model of the boiler water wall (1);

[0053] 3-2, based on the finite element stress calculation model of the water wall (1), carry out temperature field calculation under the action of combustion-structure-fluid multi-field coupling and obtain simulation temperature field distribution data, and realize fusion with the collected temperature real-time measurement data through the transfer learning model, and obtain the real-time temperature field distribution of the boiler water wall (1) based on digital twin technology;

[0054] 3-3, based on the finite element stress calculation model of the water wall (1), apply the real-time temperature field distribution data of the boiler water wall (1) obtained in the above step 3-2, carry out stress field calculation under the action of thermal-solid coupling and obtain simulation stress field distribution data;

[0055] 3-4, according to the displacement and vibration measurement data collected in the deformation sensitive area and vibration sensitive area, and combined with the simulation stress field distribution data in the above step 3-3, determine the stress failure sensitive area, and then timely arrange a plurality of strain measuring devices (31, 32~3n) to carry out strain real-time data collection;

[0056] 3-5, the simulation stress field distribution data in the above step 3-2 is fused with the collected stress real-time measurement data through the transfer learning model, and the real-time stress field distribution of the entire boiler water wall (1) is obtained based on digital twin technology; obtain the digital twin model including the real-time temperature field distribution and real-time stress field distribution of the entire boiler water wall;

[0057] Step 4, based on the field measurement point data and calculation simulation data, carry out over-limit alarm and prediction alarm;

[0058] 4-1, when the temperature, vibration, displacement values of each measuring point of the boiler water wall (1) collected in real time are greater than the set threshold values a, b, c respectively, the power plant boiler water wall state monitoring and failure early warning system (10) will generate corresponding alarm signals;

[0059] 4-2, when the temperature value of any point on the real temperature field calculated by the calculation simulation system (9) exceeds the set temperature threshold d, the power plant boiler water wall state monitoring and failure warning system (10) will generate a corresponding alarm signal.

[0060] 4-3, the calculation simulation system (9) combines the real-time stress field distribution data calculated, the real-time displacement data collected by the displacement measuring device (41, 42~4n) and the real-time vibration data collected by the vibration measuring device (51, 52~5n) to predict and evaluate the safety of the boiler water wall (1), when there is a safety risk in the evaluation, the power plant boiler water wall state monitoring and failure warning system (10) will generate a corresponding alarm signal.

[0061] Finally, it should be noted that the above is only an explanation of the present application and is not intended to limit the present application. Although the present application has been described in detail, those skilled in the art can still modify the aforementioned technical solutions or replace some of the technical features with equivalent ones. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A power plant boiler water wall state monitoring and failure warning system, comprising a field acquisition system, an upper computer system and a network communication system, characterized in that the field acquisition system comprises a plurality of measuring devices and a data acquisition device arranged on the boiler water wall; the plurality of measuring devices comprises a plurality of temperature measuring devices (21, 22-2n), a plurality of strain measuring devices (31, 32-3n), a plurality of displacement measuring devices (41, 42-4n) and a plurality of vibration measuring devices (51, 52-5n); the data acquisition device is connected to the upper computer system through the network communication system; the upper computer system comprises a computer simulation system and a failure warning system; the computer simulation system (9) is used to establish a boiler water wall physical model according to the original input data and to perform temperature field and stress field simulation calculation to obtain a preliminary temperature field distribution and a stress field distribution, and then to use a transfer learning model to fuse the collected temperature, displacement, vibration and stress data to obtain a digital twin model including the temperature field distribution and the stress field distribution of the entire boiler water wall; the failure warning system is used to perform over-limit alarm based on the field measurement point data and the real-time calculation simulation data, and to perform safety evaluation and prediction alarm based on the field measurement point data and the real-time calculation simulation data. a plurality of data acquisition devices (61, 62-6n) are connected to the plurality of measuring devices through data lines; the plurality of data acquisition devices (61, 62-6n) are distributedly arranged, wherein each data acquisition device is connected to one or more of the temperature measuring device, the strain measuring device, the displacement measuring device and the vibration measuring device through data lines.

2. The system for condition monitoring and failure warning of water wall of utility boiler according to claim 1, characterized in that, The entire structure of the water wall is divided into a plurality of array monitoring regions, and each monitoring region is provided with a data acquisition device.

3. The system for condition monitoring and failure warning of water wall of utility boiler according to claim 2, characterized in that, The network communication system adopts wired or wireless network communication; when a wired network is adopted, the plurality of data acquisition devices can be connected to a field bus and perform data interaction with a switch connected to the field bus; when a wireless network is adopted, the plurality of data acquisition devices can be connected to a ZigBee or WIFI network and perform wireless network communication with the switch.

4. The system for condition monitoring and failure warning of water wall of utility boiler according to claim 2, wherein, The plurality of temperature measuring devices (21, 22-2n), the plurality of strain measuring devices (31, 32-3n), the plurality of displacement measuring devices (41, 42-4n) and the plurality of vibration measuring devices (51, 52-5n) are directly fixed or connected to the water wall tube (11) or the fin (12) to be monitored through a positioning device.

5. The system for condition monitoring and failure warning of water wall of utility boiler as claimed in claim 1 wherein, The upper computer system comprises a control operation system; the control operation system (8) is used to provide human-computer interaction, data acquisition, data storage, statistical analysis and system setting functions.

6. The system for condition monitoring and failure warning of water wall of utility boiler as claimed in claim 1 wherein, 7. A power plant boiler water wall state monitoring and failure warning method, characterized in that it comprises the following steps: Step 1: inputting the original design parameters of the boiler water wall (1) into the computer simulation system (9) to establish a finite element stress calculation model of the boiler water wall (1) in step 3; Step 2: analyzing and determining the temperature sensitive region, the deformation sensitive region and the vibration sensitive region of the boiler water wall; ​ ​ According to the set rules, a plurality of temperature measuring devices (21, 22-2n) are arranged at the parts of the boiler water wall (1) including the temperature sensitive area, a plurality of displacement measuring devices (41, 42-4n) are arranged at the parts of the boiler water wall (1) including the deformation sensitive area, and a plurality of vibration measuring devices (51, 52-5n) are arranged at the parts of the boiler water wall (1) including the vibration sensitive area; Step 3: Based on the finite element calculation and the migration learning model, the digital twin model of the temperature field distribution and the stress field distribution of the entire boiler water wall is obtained; Step 4: Based on the field measurement point data and the calculation simulation data, the over-limit alarm and the prediction alarm are performed.

8. The power station boiler water wall state monitoring and failure warning method according to claim 7, characterized in that, Step 3 includes: 3-1, a finite element stress calculation model of the boiler water wall (1) is established; 3-2, based on the finite element stress calculation model of the water wall (1), the temperature field calculation under the action of combustion-structure-fluid multi-field coupling is carried out and the simulation temperature field distribution data is obtained, and the migration learning model is used to realize the fusion of the real-time temperature measurement data collected, and the real-time temperature field distribution of the boiler water wall (1) is obtained based on the digital twin technology.

9. The power station boiler water wall state monitoring and failure warning method according to claim 8, characterized in that, Step 3 further includes: 3-3, based on the finite element stress calculation model of the water wall (1), the real-time temperature field distribution data of the boiler water wall (1) obtained in the above step 3-2 is applied, the stress field calculation under the action of thermal-solid coupling is carried out and the simulation stress field distribution data is obtained; 3-4, according to the displacement and vibration measurement data collected in the deformation sensitive area and the vibration sensitive area, and in combination with the simulation stress field distribution data in the above step 3-3, the stress failure sensitive area is determined, and then a plurality of strain measuring devices (31, 32-3n) are arranged in time to carry out real-time data collection of strain; 3-5, the simulation stress field distribution data in the above step 3-2 is fused with the real-time stress measurement data collected through the migration learning model, and the real-time stress field distribution of the entire boiler water wall (1) is obtained based on the digital twin technology; the digital twin model including the real-time temperature field distribution and the real-time stress field distribution of the entire boiler water wall is obtained.

10. The power station boiler water wall state monitoring and failure warning method according to claim 7, characterized in that, Step 4 includes: 4-1, when the real-time collected temperature, vibration and displacement values of each measuring point of the boiler water wall (1) are greater than the set threshold values a, b and c respectively, the power station boiler water wall state monitoring and failure warning system (10) will generate corresponding alarm signals; 4-2, when the real temperature field obtained by the calculation simulation system (9) through calculation has a temperature value exceeding the set temperature threshold value d, the power station boiler water wall state monitoring and failure warning system (10) will generate corresponding alarm signals; 4-3, the calculation simulation system (9) combines the real-time distribution data of the calculated real stress field, the real-time displacement data collected by the displacement measuring device (41, 42~4n) and the real-time vibration data collected by the vibration measuring device (51, 52~5n), and predicts and evaluates the safety of the boiler water wall (1), and when there is a safety risk in the evaluation, the power plant boiler water wall state monitoring and failure early warning system (10) will generate a corresponding alarm signal.

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