Power Generation System Online Maintenance Control Modes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Power generation systems face inefficiencies during on-line maintenance due to frequent transitions triggered by minor anomalies, leading to significant costs and potential systemic issues left unchecked, as existing systems struggle to differentiate between false positives and actual faults.
Innovation Solution
Implementing a method that operates the power generation system in multiple maintenance modes, where a first mode disables automated responses to operational faults and a second mode re-enables them based on elapsed time or risk parameter thresholds, allowing for targeted maintenance while ensuring safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the system operates in a maintenance setting with automated responses enabled, then safety and reliability are improved, but false positives from minor anomalies cause frequent unnecessary transitions to maintenance mode, increasing loss of time and productivity
Solution Approach 1:
The maintenance mode is segmented into two distinct sub-modes: a first maintenance mode that disables automated responses to operational faults, and a second maintenance mode that enables automated responses. This segmentation allows the system to differentiate between minor anomalies requiring monitoring and actual faults requiring immediate automated intervention, thereby reducing false positives while maintaining safety for significant issues.
Solution Approach 2:
The system dynamically transitions between the first and second maintenance modes based on the severity and characteristics of detected anomalies. The controller adjusts the automated response behavior in real-time, disabling it for minor issues to prevent unnecessary shutdowns and maintaining it for critical faults to ensure safety, thus optimizing both productivity and reliability dynamically.
2Productivity
If the system disables automated responses during on-line maintenance, then productivity and power output are improved, but risk parameters may exceed safety thresholds without automated intervention
Solution Approach 1:
The controller continuously monitors risk parameters during operation in the first maintenance mode and provides feedback to determine whether to transition to the second maintenance mode. This feedback mechanism ensures that if risk parameters exceed predetermined safety thresholds, the system automatically re-enables automated responses by switching to the second maintenance mode, thus maintaining safety while allowing productivity benefits during normal maintenance operations.
Solution Approach 2:
The system changes the operational parameters of automated responses based on the maintenance mode. In the first maintenance mode, automated response parameters are disabled or suppressed to allow continued operation during minor anomalies. In the second maintenance mode, automated response parameters are re-enabled to ensure safety when risk parameters approach or exceed thresholds, allowing flexible adaptation to different operational conditions.
3Reliability
If monitoring thresholds for operational faults are set low to ensure safety, then reliability is improved, but minor anomalies trigger frequent transitions to maintenance mode, increasing loss of time and maintenance costs
Solution Approach 1:
The monitoring system is segmented into two operational states: the first maintenance mode with relaxed thresholds that allow continued operation during minor anomalies, and the second maintenance mode with strict thresholds that ensure safety through automated responses. This segmentation resolves the contradiction by applying appropriate threshold strictness based on the current maintenance mode, reducing unnecessary transitions while maintaining safety monitoring.
Solution Approach 2:
The monitoring thresholds are dynamically adjusted based on the current maintenance mode. During the first maintenance mode, the system operates with higher tolerance thresholds to minimize unnecessary transitions and maintain productivity. When transitioning to the second maintenance mode, thresholds become stricter to ensure safety through automated responses, allowing the system to adapt threshold sensitivity to operational needs in real-time.
Data Source
AI summary
Embodiments of the disclosure provide a method for controlling a power generation system during on-line maintenance. The method includes operating the power generation system in a first maintenance mode, which causes a controller of the power generation system to disable an automated response to at least one operational fault of the power generation system; monitoring a risk parameter of the power generation system or at least one sensor within the power generation system while operating the power generation system in the first maintenance mode; and operating the power generation system in a second maintenance mode in response to detecting an override command, an elapsed time exceeding a time limit, or the monitored risk parameter exceeding a safety threshold. The second maintenance mode causes the controller of the power generation system to enable the automated response to the at least one operational fault of the power generation system.