Monitoring system

• US 6,157,310 A
• Filed: 09/10/1999
• Issued: 12/05/2000
• Est. Priority Date: 03/13/1997
• Status: Expired due to Fees

• Current Assignee: Turbine Services Ltd.
• Original Assignee: Intelligent Applications Limited
• Inventors: Milne, Robert William, Nicol, Charles Jarvis
• Primary Examiner(s): Hofsass, Jeffery A.
• Assistant Examiner(s): Huang, Sihong
• Application Number:
  US09/396,678
• Time in Patent Office: 452 Days
• Field of Search: 340/679, 340/522, 340/525, 340/517, 340/519, 340/521, 702/58, 702/59, 702/182-187, 701/35
• US Class Current: 340/679
• CPC Class Codes: G05B 23/0251 Abstraction hierarchy, e.g. "complex systems", i.e. system is divided in subsystems, subsystems are monitored and results are combined to decide on status of whole system

Abstract

The present invention provides a monitoring system (30) for monitoring operation of dynamic plant apparatus (10, 100). Electronic processing means (31, 32, 33) is provided for processing the electrical parameter signals provided by sensors (11-15) and is capable of thereby producing a plurality of different fault signals. Display means (34) is provided for displaying fault information to a user of the monitoring system (30), the display means (34) being controlled by the fault signals produced by the electronic processing means (31, 32, 33). The electronic processing means (31, 32, 33) compares the values of at least some of the measured parameter signals with limit values stored in memory by the electronic processing means (31, 32, 33) and when the comparison shows that the value of a measured parameter signal is outside the respective limit value the electronic processing means (31, 32, 33) produces a respective basic fault token signal. There are storage means with a plurality of different storage sites, each storage site having a plurality of storage locations for a different predetermined variety of basic fault token signals. When all storage locations of a storage site are filled by basic fault token signals then the electronic processing means (31, 32, 33) produces a high level fault signal, causing the display means (34) to display a fault message.

Claims

1. A monitoring system for monitoring operation of dynamic plant apparatus comprising:

a plurality of sensors measuring dynamically varying operating parameters of the monitored dynamic plant apparatus and for generating electrical parameter signals indicative of the measured operating parameters;

electronic processing means for processing the electrical parameter signals and which is capable of thereby producing a plurality of different fault signals each of which respectively indicates that the monitored dynamic plant apparatus has a respective one of a plurality of faults;

display means for displaying fault information to a user of the monitoring system, the display means being controlled by the fault signals produced by the electronic processing means;

wherein;

the electronic processing means compares the values of at least some of the measured parameter signals each with respective predefined limit values stored in memory by the electronic processing means and when the comparison shows that the value of a measured parameter signal is outside the respective limit value the electronic processing means produces a respective basic fault token signal,

characterised in that;

the electronic processing means has storage means for storing electrical signals which operates in a clocked manner and stores the basic fault token signals;

the storage means has a plurality of different storage sites, each storage site having a plurality of storage locations for a different predetermined variety of basic fault token signals; and

when all storage locations of a storage site are filled by basic fault token signals produced in a prespecified clocked interval then the electronic processing means produces a high level fault signal, each storage site having an associated high level fault signal, the high level fault signal causing the display means to display a fault message.

2. A monitoring system as claimed in claim 1 wherein the electronic processing means compares the value of a first measured parameter signal with the value of a second measured parameter signal and if after a change of the value of the first measured parameter signal there is not a related change of value of the second measured parameter signal within a predefined time period then the electronic processing means produces a basic fault token signal.

3. A monitoring system as claimed in claim 1 wherein on generation of the high level fault signal the display means displays information both regarding the high level fault and also the basic faults associated with the high level fault signal.

4. A monitoring system as claimed in claim 1 wherein the storage means stores predefined relationships between high level fault signals and basic fault token signals and when a high level fault signal is produced the monitoring system can determine which basic fault token signals, other than those in the storage site related to said high level fault signal, result from the detected high level fault, and information regarding such resulting basic faults is displayed by the display means.

5. A gas turbine having a monitoring system as claimed in claim 1.

6. A gas turbine as claimed in claim 5, wherein the measured dynamically varying operating parameters include:

a current to a servo-motor for a second stage nozzle of the gas turbine;

a desired position control signal for controlling position of the second stage nozzle;

a position feedback signal indicative of a measured position of the second stage nozzle;

a signal indicative of rotational speed of a compressor shaft of the gas turbine; and

a signal indicative of rotational speed of an output shaft of the gas turbine.

7. A gas turbine as claimed in claim 6 wherein the monitoring system produces a first basic fault token signal when the current to the servo-motor exceeds a first predetermined threshold.

8. A gas turbine as claimed in claim 6 wherein the monitoring system produces a second basic fault token signal when the desired position control signal for controlling position of the second stage nozzle exceeds a second predefined threshold.

9. A gas turbine as claimed in claim 6 wherein the monitoring system produces a third basic fault token when the signal indicative of the rotational speed of the compressor shaft exceeds a third predefined threshold.

10. A gas turbine as claim in claim 6 wherein the monitoring system produces a fourth basic fault token signal when the measured position of the second stage nozzle fails to match the desired position of the second stage nozzle within a first predefined time period.

11. A gas turbine as claimed in claim 6 wherein the monitoring system produces a fifth basic fault token signal when a comparison of the signal indicative of the rotational speed of the output shaft with a turbine output shaft reference speed signal shows that the output shaft speed does not match the reference speed within a second predefined time period.

12. A gas turbine as claimed in claim 6 wherein the monitoring system produces:

a first basic fault token signal when the current to the servo-motor exceeds a first predefined threshold;

a second basic fault token signal when the desired position control signal for controlling position of the second stage nozzle exceeds a second predefined threshold;

a fourth basic fault token signal when the measured position of the second stage nozzle does not match the desired position of the second stage nozzle within a first predefined time period; and

the monitoring system produces a high level fault token signal indicating failure of a servo-motor of the second stage nozzle when a storage site has three storage locations filled one each with the first, second and fourth basic fault token signals within a specified time period.

13. A gas turbine as claimed in claim 12 wherein the storage means stores predefined relationships between the high level fault signal indicating failure of the servo-motor of the second stage nozzle and:

a third basic fault token signal which is produced when the signal indicative of compressor shaft speed exceeds a specified threshold; and

a fifth basic fault token signal which is produced when a comparison of the signal indicative of the rotational speed of the output shaft with a turbine output shaft reference speed signal indicates that the rotational speed of the output shaft does not match the reference speed within a second predefined time period; and

wherein;

the monitoring system uses the predefined relations to record that production of the third and fifth basic fault token signal can be accounted for by a high level fault of saturation of the servo-motor of the second stage nozzle and when the high level fault token signal indicating failure of the servo-motor is produced the monitoring system displays on the display means a message detailing recent third and fifth basic fault token signals which have been produced and notes that such signals can be accounted for by the high level fault detected.

14. A gas turbine as claimed in claim 5 wherein the measured dynamically varying parameters include:

a signal indicative of running gas pressure; and

a signal indicative of current supplied to a running gas speed ratio valve.

15. A gas turbine as claimed in claim 14 wherein a sixth basic fault token signal is produced when the signal indicative of the running gas pressure exceeds a sixth predefined limit and a seventh basic fault token signal is produced when the signal indicative of current supplied to a running gas speed ratio valve exceeds a seventh predefined limit.

16. A gas turbine as claimed in claim 15 wherein a high level fault token signal indicating failure of a coil of running gas speed ratio valve is produced when a storage site has two storage locations filled one each with the sixth and seventh basic fault token signals in a specified period.

17. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a change in position of a gas fuel valve is sensed by a sensor without a corresponding change in gas fuel flow being sensed by another sensor within a predefined time period.

18. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a change in temperature of gas discharged from a compressor part of the gas turbine is sensed by a temperature sensor without a corresponding change in flow of fuel gas being sensed by a gas flow sensor within a predefined time period.

19. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a change in flame intensity is sensed by a flame detector sensor without a corresponding change in gas control valve position reference signal within a predefined time period.

20. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in power output of the electricity generator is sensed by a power sensor without a corresponding change in temperature of a wheel space of a turbine of the gas turbine being sensed by a temperature sensor within a predefined time period.

21. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in fuel gas flow rate is sensed by a flow rate sensor without a corresponding change in power output of the electricity generator being sensed by a power sensor within a predefined time period.

22. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in power output of the electricity generator is sensed by a power sensor without a corresponding change in flame intensity being sensed by a flame detector within a predefined time period.

23. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in power output of the electricity generator is sensed by a power sensor without a corresponding change in temperature of exhaust gasses of the gas turbine being sensed by a temperature sensor within a predefined time period.

24. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in temperature of a stator of the electricity generator is sensed without a corresponding change in the maximum temperature of air drawn into a compressor part of the gas turbine being sensed by a temperature sensor within a predefined time period.

25. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in temperature of a stator of the electricity generator is sensed by a temperature sensor without a corresponding change in temperature of the exhaust gasses of the gas turbine being sensed by another temperature sensor within a predefined time period.

26. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when a change in temperature of a bearing of the electricity generator is sensed by a temperature sensor without a corresponding change in temperature of cooling gas entering the electricity generator being sensed by another temperature sensor within a predefined time period.

27. A gas turbine as claimed in claim 5 wherein the gas turbine is connected to an electricity generator and drives the electricity generator to produce electrical power, sensors are provided to sense dynamically varying operating parameters of the electricity generator and a basic fault token signal is produced when the value of electrical power output of the generator as sensed by a power sensor is less than zero for more than a predefined time period.

28. A gas turbine as claimed in claim 5 wherein the gas turbine is provided with NO_x control apparatus for controlling NO_x emissions in exhaust gasses of the gas turbine by injecting steam into the exhaust gasses and sensors are provided to monitor dynamically varying operating parameters of the NO_x control apparatus and a basic fault token signal is produced when a change in the rate of flow of steam to combustors of the gas turbine is sensed by a flow meter without a corresponding change in temperature of exhaust gasses of the gas turbine being sensed by a temperature sensor within a predefined time period.

29. A gas turbine as claimed in claim 5 wherein the gas turbine is provided with NO_x control apparatus for controlling NO_x emissions in exhaust gasses of the gas turbine by injecting steam into the exhaust gases and sensors are provided to monitor dynamically varying operating parameters of the NO_x control apparatus and a basic fault token signal is produced when a change in injection pressure of a steam injector of the NO_x control apparatus is sensed by a pressure sensor without a corresponding change in flow rate of steam to combustors of the gas turbine being sensed by a flow meter within a predefined time period.

30. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a change in temperature of gasses discharged by a compressor part of the gas turbine is sensed by a temperature sensor without a corresponding change in temperature of gasses at the inlet of the compressor part being sensed by another temperature sensor within a predefined time period.

31. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a change in temperature of compressed gas leaving a compressor part of the gas turbine is sensed by a temperature sensor without a corresponding change in temperature of exhaust gasses of the gas turbine being sensed by another temperature sensor within a predefined time period.

32. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a change in temperature of exhaust gasses of the gas turbine is sensed without a corresponding change in fuel gas intervalve pressure being sensed by a pressure sensor within a predefined time period.

33. A gas turbine as claimed in claim 5 wherein a basic fault token signal is produced when a digital master protection signal changes value from 1 to 0.

34. A gas turbine as claimed in claim 24 wherein the monitoring system produces a high level fault token signal indicating a mechanical fault in the electricity generator when a storage site has two storage location filled within a specified time period one each with the following basic fault token signals:

the basic fault token signal indicating an increase in the bearing temperature without a corresponding change in the temperature of the cooling gas entering the electricity generator; and

a basic fault token signal indicating a change in the stator temperature without a corresponding change in the maximum temperature of air drawn into the compressor part of the gas turbine.

35. A gas turbine as claimed in claim 19 wherein the monitoring system produces a high level fault token signal indicating a problem in steam supply to the combustors when a storage site has two storage locations filled within a specified time period one each with the following basic fault token signals:

the basic fault token signal indicating a change in sensed flame intensity without a corresponding change in the gas control valve position reference signal; and

a basic fault token signal indicating a change in the injection pressure of the steam without a corresponding change in flow rate of steam to the combustors of the gas turbine.

36. A gas turbine as claimed in claim 22 wherein the monitoring system produces a high level token signal indicating a problem of air flow disturbance in the gas turbine affecting the power output when a storage site has first and second storage locations filled in a specified time period one each with the following basic fault token signals:

the basic fault token signal indicating a change in power output of the electricity generator is sensed without a corresponding change in flame intensity; and

a basic fault token signal indicating a change in sensed power output without a corresponding change in the temperature of the exhaust gases; and

when in the same specified time period a third storage location of the storage site remains unfilled by a basic fault token signal indicating that change in flow rate of fuel gas is not followed by a corresponding change in the sensed power output.

37. A gas turbine as claimed in claim 19 wherein the monitoring system produces a high level fault token signal indicating a problem with turbine combustors when a storage site has two storage locations filled within a specified time period one each with the following basic fault token signals:

a basic fault token signal indicating a change in flame intensity without a corresponding change in gas control valve position reference signal; and

a basic fault token signal indicating a change in temperature of the exhaust temperature of the gas turbine without a corresponding change in fuel gas intervalve pressure.

38. A gas turbine as claimed in claim 30 wherein the monitoring system produces a high level fault token signal indicating a problem with a temperature change in the compressor part of the gas turbine when a storage site has two storage locations filled within a specified time period one each with the following basic fault token signals:

a basic fault token signal indicating a change in the temperature of the gasses discharged by the compressor part of the turbine without a corresponding change in temperature of the gasses at the inlet of the compressor part; and

the basic fault token signal indicating a change in the temperature of the gasses discharged by the compressor part of the turbine without a corresponding change in the exhaust temperature of the gas turbine.

39. A gas turbine as claimed in claim 27 wherein the monitoring system produces a high level fault token signal indicating a problem with the generator being in reverse power mode when a storage site has two storage locations filled within a first specified time period one each with the following basic fault token signals:

a basic fault token signal indicating a change in value of the digital master protection signal from 1 to 0; and

a basic fault token signal indicating that the electrical power output of the electricity generator is less than zero.

40. A gas turbine as claimed in claim 39 wherein if the two storage locations remain filled for more than a second specified time period the monitoring system produces a high level fault token signal indicating a major fault.