WO1996007958A1

WO1996007958A1 - Diagnostic advisor for combustion turbine operations

Info

Publication number: WO1996007958A1
Application number: PCT/US1995/010998
Authority: WO
Inventors: Maurice A. Jenkins; Ronald S. Thomas
Original assignee: Westinghouse Electric Corporation
Priority date: 1994-09-08
Filing date: 1995-08-29
Publication date: 1996-03-14

Abstract

A diagnostic advisor that performs two main functions - diagnostic and control - is disclosed. In association with the diagnostic function, the diagnostic advisor helps the operator quickly take appropriate action through startup, operation and shutdown of a remote generating facility. In association with the control function, the diagnostic advisor provides an efficient interface between the operator and the system. When a malfunction is detected, the diagnostic advisor immediately displays a malfunction icon on whatever screen is currently being displayed. The icon alerts the operator that a malfunction has occurred or is immanent. An expert system automatically processes monitored information and compiles a diagnostic analysis and a list of one or more recommended options. The diagnostic advisor allows the operator to view a list of probable diagnoses, to view a recommended information screen that best shows the problem variables identified by the diagnostic advisor, or to continue viewing the current screen. The control function of the diagnostic advisor allows the operator to select for viewing, at any time, a recommendation screen, an option menu, the previous screen, or a summary screen.

Description

DIAGNOSTIC ADVISOR FOR COMBUSTION TURBINE OPERATIONS

The present invention relates generally to a computer-implemented process and system for providing information to an operator of a complex system. More particularly, the present invention relates to a computer- implemented "Diagnostic Advisor" for providing information in, an optimal manner to an operator of a combustion turbine plant.

BACKGROUND OF THE INVENTION

One preferred application of the present invention is in connection with the operation of a combustion turbine plant and more particularly in connection with the remote operation of a combustion turbine plant. Therefore, the background of the invention and preferred embodiments of the invention are described below with reference to a system for remotely controlling a combustion turbine plant. It should be understood, however, that the present invention is by no means limited to applications involving the operation of a combustion turbine plant. Accordingly, except where they may be expressly so limited, the scope of protection of the claims at the end of this specification is intended not to be limited to applications of the invention involving combustion turbines.

The assignee of the present invention (Westinghouse Electric Corporation) employs remote startup equipment at its Orlando, Florida Diagnostic Operations Center to start three combustion turbines located in Virginia. The remote startup capability allows the local utility to provide continuous power to its customers after regular business hours without staffing the plant 24 hours a day. Upon receiving a request from the plant operator, the remote Diagnostic Operations Center can start the combustion turbines remotely, providing full unit power within minutes (e.g., 45 minutes) of the request.

The system described above is schematically depicted in Figure X and is discussed in greater detail below in connection with the detailed description of preferred embodiments of the present invention. Briefly, the Diagnostic Operations Center employs a microprocessor-based system including graphics and communications cards. The system transmits and receives data over telephone lines with the use of modems and multiplexers. The turbine plant operators can transfer control of the plant to the Diagnostic Operations Center operators by turning a switch on a keyboard. The transfer of control enables the Diagnostic Operations Center operators to start the turbines remotely and to remotely manipulate the plant breakers to supply power to all equipment, as necessary. It typically takes approximately 14 minutes from startup to generator synchronization for each unit and 10 more minutes to bring each unit to full load. The power demanded by the starting motors is typically too high to allow all of the turbines to be started at once. Therefore, the turbines are typically started sequentially. Accordingly, the Diagnostic Operations Center operator must carefully sequence the startups to meet the prescribed (e.g., 45 minute) requirement for bringing all turbine units to full load.

There are a number of advantages offered by this system. For example, the Diagnostic Operations Center's remote startup capability allows Westinghouse to provide 24- hour coverage and 45-minute availability of the plant's full output to meet the local community's variable load demands, although the plant is not staffed 24 hours a day. In addition, the Diagnostic Operations Center's remote startup capability enables Westinghouse to receive immediate notification of any event that might prevent the plant from responding to a dispatch call, and to review combustion turbine operating data on-line to verify operating parameters and equipment status.

Notwithstanding its advantages, there are several problems with this system. For example, there are various screen displays that are used to present information to the operator. Currently, the operator must know (through training or experience) which screen best displays the information needed. For example, in one embodiment of the system, the necessary information is displayed on twenty-three different screens which are entirely filled with data and graphic displays. Screens must be viewed in the proper sequence for successful unit operation. Several screens display overlapping information about the same system. For example, some vibration data is shown on five different screens. Considerable knowledge is required by the operator to find the screen that best accesses specific information. Furthermore, during startup of peaking units, the operator is focused on starting up multiple units together in a contractually specified period of time. The operator must stay alert to an overwhelming amount of data. For example, alarms sound to signal that normal steps are taking place. During this time, the visible screen is the startup screen for the current unit and twenty-two other screens are not visible. The operator may be distracted from watching the screens for the other units. If a malfunction occurs, the operator may be unaware of it. When aware of a problem, the operator must rely on experience to know which screen will best show the most important and useful information. Lack of information about a malfunction can have serious consequences. For example, lubricating oil^* may be lost, a blade may be lost, a combustor basket may be burned, a transition tube may collapse, or the temperature of a rotor cavity may become too high as a consequence of the operator being overwhelmed by the plethora of information available. Therefore, it is extremely important to present the operator the information most useful to him for dealing with any problems that might arise, and to do so immediately.

SUMMARY OF THE INVENTION Briefly, the present invention provides a diagnostic advisor that performs two main functions — diagnostic and control. In association with the diagnostic function, the diagnostic advisor provides a means for helping the operator quickly take appropriate action through startup, operation, and shutdown. In association with the control function, the diagnostic advisor provides a convenient and efficient interface between the operator and the system.

In the preferred embodiment of the invention described herein below, the diagnostic advisor immediately displays a malfunction icon on whatever screen is currently being displayed. The icon, which is coded to identify the unit or system involved, alerts the operator (for example, by blinking and/or by employing a color code) that a malfunction has occurred or is immanent. In addition, an expert system automatically processes monitored information and compiles a diagnostic analysis and a list of one or more recommended options. The diagnostic advisor allows the operator to view a list of probable diagnoses (which is also a menu to a best monitoring information screen for each diagnosis) , to view a recommended information screen that best shows the problem variables identified by the diagnostic advisor, or to continue viewing the current screen. The control function of the diagnostic advisor allows the operator to select for viewing, at any time, a recommendation screen, an option menu, the previous screen viewed, or a diagnostic summary screen. The present invention provides a system for alerting the operator to a malfunction immediately. In addition, the inventive system immediately informs the operator what and where the problem is and how urgent it is. The invention also makes an expert system available to advise the operator of a list of one or more best action options. The invention provides a way of giving an experienced operator immediate, expert corroboration, which allows the operator to act more quickly. The present invention also provides a continuous training tool, since the expert system feature of the diagnostic advisor continuously teaches the operator or user, which keeps even experienced operators well-trained. The invention also provides a means for improving plant availability, and saving costs in contractual failure-to- startup penalty fees. (For example, for peaking units, the penalty can be $15,000 per startup time period failure). Moreover, the present invention provides a means for saving costs in operation damage, including repair expenses and costs associated with the loss of a unit for down time. (For example, opening and closing a unit for repair can cost approximately $1,000,000).

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a block diagram of one preferred embodiment of the present invention.

Figures 2A through 2S depict various screen displays provided by the system.

Figure 3 is a schematic diagram of a diagnostic advisor in accordance with the present invention.

Figure 4 is a depiction of a malfunction icon in accordance with the present invention.

Figure 5 is a depiction of a diagnostic summary screen in accordance with the present invention. DETAILED DESCRIPTION OF PREFEF^.ED EMBODIMENTS

Figure 1 schematically depicts one preferred embodiment of a combustion turbine monitoring and control system in accordance with the present invention. The system comprises a plurality of generators 10 and associated combustion turbines 12. The generators and turbines are respectively connected to data links 14, 16 coupled to a data highway 18. The data highway 18 provides access to a variety of monitored parameters associated with the generators and turbines from a control room 20. The control room houses a computer/console 22, which is coupled to a modem 24. The modem 24 is coupled to a phone line 26, which in turn is coupled to a modem 28 and computer/console 30 at a remote location.

According to the present invention, a software- implemented diagnostic advisor 40 manages the presentation of information and screen displays to the operator viewing the remote console 30. Before describing the functionality of the diagnostic advisor 40, a brief review of the various screens which may be presented or available for presentation to the remote operator will be provided. Figure 2A depicts an exemplary startup screen. In particular, this screen is a "Unit No. 1 — Selection Screen." As shown, this screen includes a master run field, a speed control field, a temperature control field, a power factor control field, a water injection control field, two breaker control fields, and so on. These various fields provide an interface to the operator for use in controlling various operations of the combustion turbine unit in question, which in this case is Unit No. 1. The meanings of the various terms presented in this screen display and the other screen displays discussed below are not described in detail in this specification, since such meanings will be apparent to those skilled in the art.

Figure 2B depicts a "Combustion Turbine Longitudinal" screen for combustion turbine unit No. l. As shown, this screen depicts a variety of information. For example, the displayed information relates to inlet air temperature and pressure; air flow velocity; blade valves; blade path temperatures; exhaust gas temperature, and so on.

Figure 2C depicts a "Trip Screen" providing information regarding a number of breakers associated with combustion turbine unit No. 2.

Figure 2D depicts a "Fuel Oil Supply System" screen providing information regarding the fuel oil supply system of combustion turbine unit No. 1. It should be noted in connection with this screen and the other screens that there will often be overlap with respect to the subsystem-related information provided by the various screens. For example, the "fuel oil supply system" screen and a number of other screens display information regarding blade path temperature.

Figure 2E depicts a "Gas Fuel System" screen displaying information regarding the gas fuel system for combustion turbine unit No. 2.

Figure 2F depicts a "Lube Oil System" screen.

Figure 2G depicts a "Hot Gas Path" screen.

Figure 2H depicts an "Overall-Start to Synchronization" screen. Figure 21 depicts a "Turbine Functions" screen.

Figure 2J depicts a "Combustion Cycle-Power Generation Mode" screen.

Figure 2K depicts a "Overall - 89% speed to full power" screen. Figure 2L depicts a "Generator Jacking/Lube Oil

System" screen.

Figure 2M depicts a "BOP Protective Relay Alarms" screen.

Figure 2N depicts a "AUX Power Overview" screen. Figure 20 depicts a "Transformer Alarms" screen.

Figure 2P depicts a "Remote Operation Overview" screen.

Figure 2Q depicts a "13.8 KV System Overview" screen. Figure 2R depicts a "Fuel Forwarding Overview" screen.

Figure 2S depicts a "Water Injection System" screen.

From the above brief review of the various screens for presentation to the operator, it is apparent that both experienced and inexperienced operators will often become overwhelmed by the plethora of information available. The present invention provides a computer-implemented process for coordinating and managing the presentation of information to the operator so that he or she will be able to most effectively use the information available.

Figure 3 schematically depicts the features of the diagnostic advisor software in accordance with the present invention. As shown, the diagnostic advisor 40 comprises a diagnostic component and a control component. The diagnostic component includes a component 42 for displaying a malfunction icon (see Figure 4); an expert system component 44 for analyzing the monitored information and providing a diagnosis or a list of possible diagnoses of any malfunctions that arise; a component 46 for alerting the operator of any problems or malfunctions; and a component 48 for advising the operator of one or more best action options. The control component includes an operator interface 50 for switching screens and selecting options.

Referring now to Figure 4, one embodiment of the present invention provides a malfunction icon 60 whenever a malfunction is detected. The malfunction icon 60 is displayed on the operator's console along with whatever screen display is currently being viewed. The malfunction icon 60 includes a plurality of fields, including a first field 62, a second field 64, a third field 66, and a fourth field 68. In addition, in a central region 70 the unit number or some other identification of the combustion turbine unit in question is displayed. As indicated in the figure, the first field 62 provides a means whereby the operator may instruct the system to display the newest diagnosis screen. The second field 64 provides a means whereby the operator may instruct the system to display a diagnostic summary screen (Figure 5) . The third field 66 provides a means whereby the operator may instruct the system to display a description of the problem or problems detected and a recommendation as to the appropriate action for the operator to take. The fourth field 68 allows the operator to instruct the system to display, or go back to, an original screen, which may be any pre-specified screen in a series of screen displays. Preferably, when the operator selects the third field 66, the system will not only display a description of the detected problem and the appropriate action to take in response thereto, but will also display a description of what will happen if the recommended action is not taken. Figure 5 depicts an exemplary diagnostic summary screen 80. As shown, the diagnostic summary screen will preferably include a first field 82 for displaying the identification of the unit number in question. In addition, the diagnostic summary screen preferably will include another field 84 for displaying a confidence factor for the respective diagnoses, which are displayed in order of importance and/or color coded in a third field 86.

Claims

WE CLAIM;

1. A computer-implemented process for providing information to an operator of a system comprising one or more machines and a monitoring system, said monitoring system including means for measuring a plurality of parameters and presenting a plurality of screen displays each representing one or more of said parameters, the process comprising the steps of:

(a) maintaining for each machine a list of one or more diagnoses based upon measured parameters corresponding to that machine;

(b) presenting an icon to the operator, said icon indicating a possible malfunction and comprising plural fields, each field allowing the operator to select an action; and (c) automatically determining the most relevant screen display corresponding to at least one of said diagnoses and displaying said most relevant screen display.

2. A process as recited in claim 1, wherein a first field of said icon, when selected, causes the system to display a diagnosis of a malfunction of said machine.

3. A process as recited in claim 2, further comprising displaying a list of diagnoses and a confidence level for each diagnosis in said list.

4. A process as recited in claim l, wherein at least one of the machines is a combustion turbine.

5. A process as recited in claim 3, wherein at least one of the machines is a combustion turbine.

6. A process as recited in claim 1, wherein the process comprising steps a through c is performed remotely from the system being monitored.

7. A process as recited in claim 5, wherein the process comprising steps a through c is performed remotely from the system being monitored.

8. A computer-implemented process for providing information to an operator of a system comprising one or more machines, comprising the steps of:

(a) monitoring said machine to obtain measurements of a plurality of parameters;

(b) presenting a plurality of screen displays each representing one or more of said parameters;

(c) maintaining for each machine a list of one or more diagnoses based upon measured parameters corresponding to that machine; and

(d) automatically determining the most relevant screen display corresponding to at least one of the diagnoses and displaying said most relevant screen display.

9. A process as recited in claim 8, further comprising the step of displaying an icon, said icon signalling a malfunction and comprising plural fields, each field allowing the operator to select an action.

10. A process as recited in claim 9, wherein a first field of said icon, when selected, causes the system to display a diagnosis of a malfunction of said machine.

11. A process as recited in claim 10, further comprising displaying a list of diagnoses and a confidence level for each diagnosis in said list.

12. A process as recited in claim 11, wherein at least one of the machines is a combustion turbine.

13. A process as recited in claim 12, wherein the process is performed remotely from the machine being monitored.

14. A system for providing information to an operator of one or more machines, comprising:

(a) means for monitoring said machine to obtain measurements of a plurality of parameters;

(b) means for presenting a plurality of screen displays each representing one or more of said parameters;

(c) means for maintaining for each machine a list of one or more diagnoses based upon measured parameters corresponding to that machine; and

(d) means for automatically determining the most relevant screen display corresponding to at least one of the diagnoses and displaying said most relevant screen display.

15. A system as recited in claim 14, further comprising means for displaying an icon, said icon signalling a malfunction and comprising plural fields, each field allowing the operator to select an action.

16. A system as recited in claim 15, wherein a first field of said icon, when selected, causes the system to display a diagnosis of a malfunction of said machine.

17. A system as recited in claim 16, further comprising means for displaying a list of diagnoses and a confidence level for each diagnosis in said list.

18. A system as recited in claim 17, wherein at least one of the machines is a combustion turbine.

19. A system as recited in claim 18, wherein the system remotely connected to the machine being monitored.