CN101320259A - A method and system for life management of important components of a unit generator set host - Google Patents

Abstract

The invention relates to a life management system for important components of a unit generating set main engine, which is characterized in that the web server is respectively connected with a calculation/application server, a database server and a client browser, the calculation/application server is connected with a database server, and the database server is connected through an external The system interface is connected with the generator set host data acquisition system and parameter measurement points. The management method is: determine the transient life loss of the important parts of the main engine of the online calculation unit, calculate the remaining low-cycle fatigue life of the important parts of the main engine of the unit, the remaining creep life, Remaining life of generator rotor under combined action of low cycle fatigue and torsional vibration fatigue and under combined action of corrosion and wear. The advantage of the present invention is that a set of life management system is adopted to realize the on-line calculation and monitoring of transient life loss and remaining life of multiple important components of the four main engines of the unit generating set.

Description

A method and system for life management of important components of a unit generator set host

technical field

The invention relates to a method and system for life management of important components of a unit generator set, which are applied to equipment management for the operation and maintenance of a unit generator set, and belong to the technical field of power generation engineering and generator sets.

Background technique

The four major hosts of power plant generator sets are steam turbine, boiler, generator and transformer. The important components include: rotor, cylinder and valve casing of steam turbine, steam drum or steam-water separator, header, pipeline, superheater and reheater of boiler The tubes of the generator, the water wall and the economizer tube, the rotor and stator winding insulation of the generator, and the winding insulation of the main transformer. The main components of the generator set are expensive to manufacture, and the consequences of damage are serious. In order to reasonably use the life of important components of the main engine of the generator set, the existing technologies of the life management of the important components of the main engine of the generator set reported in the open literature are all life management for a single important component of a certain main engine of a generator set, which is used to guide the operation, Maintenance and equipment management. Since a main engine of a generating set has four main engines, and one main engine has multiple important components, these important components of the main engine need to be managed at the same time. There are two deficiencies in using the existing technology for life management: the first one is that an important part of a main engine of a generator set is equipped with a life management system, and the life management of multiple important parts of a generator set with multiple main engines Dozens of life management systems need to be configured, which requires high investment and is inconvenient to use and maintain. The second problem is to guide the operation or arrangement of the entire generator set based on the life management results of an important component of a certain host of the generator set Planning maintenance, considering the problem is not yet comprehensive.

Contents of the invention

The purpose of the present invention is to provide a method and system for realizing the life management of the important parts of the four main engines of the unit generator set by using a set of life management system.

In order to achieve the above objectives, the technical solution of the present invention is to provide a life management system for important components of the main engine of a unit generating set, which is characterized in that it consists of a life calculation/application server and software, a database server, an external system interface, and data acquisition of the main engine of the generating set The system DAS is composed of parameter measuring points, web server and client browser. The web server is respectively connected to the computing/application server, database server and client browser. The computing/application server is connected to the database server. The database server is connected to the external system interface. The generator set host data acquisition system is connected to the parameter measuring point.

The parameter measuring points are: the speed of the steam turbine, the power of the unit, the steam pressure in front of the main steam valve, the steam temperature in front of the main steam valve, the steam temperature after the regulating stage, the metal temperature of the high pressure inner cylinder at the regulating stage, the Steam pressure, steam temperature in front of the medium pressure main steam valve, metal temperature of the medium pressure inner cylinder, medium exhaust steam pressure or four extraction steam pressure, medium exhaust steam temperature or four extraction steam temperature, medium and low pressure connecting pipe temperature, condenser vacuum; Main steam outlet flow, temperature and pressure of the boiler, boiler reheat steam outlet flow, temperature and pressure, boiler feed water flow, temperature and pressure, reheat steam inlet flow, temperature and pressure, steam drum or steam-water separator and header and pipe wall temperature measurement points; generator active power, three-phase current and voltage, generator shaft torsional vibration signal, generator stator winding insulation working temperature.

A method for managing the life of important parts of a main unit generator set, characterized in that the software for calculating the life loss and remaining life of important parts of a unit generator set main unit written in C language runs on a calculation/application server and is applied to a unit generator set The life management of important components of the main engine, the method is as follows: Step 1: Store online monitoring data

Through the external system interface, the flow, pressure, temperature, speed, power, wall temperature, current, voltage, torsional vibration signal, working temperature, etc. collected online by the data acquisition system DAS system of the main engine of the generator set are collected every Δτ=1 minute to 30 minutes The measuring point data is stored in the database server;

Step 2: Enter basic data

Through the user terminal of the maintenance department, input the cumulative running hours S _h , cumulative cold start times n _c , and cumulative warm state Times n _w , accumulative number of hot starts n _h , accumulative number of extremely hot starts n _r , accumulative number of large load changes n ₁ , accumulative times of medium load changes n ₂ , accumulative times of small load changes n ₃ ; the end of each planned maintenance Finally, the maintenance department enters the measured wall thickness δ of the pipe into the database server through the web server on the client browser;

Step 3: Determine the life evaluation items of important components of the main engine

According to the experience accumulated in the life management of generator sets for many years, the life evaluation items of important components of the defined unit generator set host are shown in Table 1

[Table 1]

Step 4: online calculation of the transient life loss d _i and d _v of important parts of the generator unit main engine is applied to the computer software installed on the computing/application server for the life of the important components of the generator unit main engine, and the prior art is used to calculate the unit generator main engine online Transient low cycle fatigue life loss d _i and transient torsional vibration fatigue life loss d _v of important components;

Step 5: Put forward suggestions for optimal operation of unit generator sets

The low-cycle fatigue life loss d _i and torsional vibration fatigue life loss d _v calculated online for the important components of the main engine of the generator set are respectively related to the low-cycle fatigue life loss limit value [d] and the torsional vibration fatigue life loss [d _v ] for comparison, if d _i ≤0.8[d], the change rate of main steam temperature and load change rate of the generator set main engine shall operate according to the specified values in the "Operation Regulations for Generator Set Main Engine"; if d _v ≤[d _v ], The unit is operating normally. In the case of d _i >0.8[d], the optimization operation suggestions are put forward according to the following four situations: If 0.8[d]<d _i ≤[d], reduce the change rate of main steam temperature and load change rate of the generator set; If [d]<d _i ≤1.05[d], the rate of change of the main steam temperature and the load of the generator set are controlled to be 0; if 1.05[d]<d _i ≤1.25[d], an alarm will be issued, Trip and stop after 1 minute; if d _i > 1.25[d], an alarm will be issued, and trip and stop will be triggered after 1 minute; in the case of d _v > 0.8[d _v ], an alarm will be issued;

Step 6: Calculate the remaining low-cycle fatigue life of the important components of the main engine of the generator unit y _rlni maintenance department The technicians of the client browser send instructions to the calculation/application server through the web server, and the calculation/application server reads the required information from the database server The accumulative start-up times and accumulative load change times, the cold-state start-stop life N _fc , the warm-state start-stop life N _fw , the hot start-stop life N fc Stop life N _fh , extremely hot start-stop life N _fr , large load change life N _f1 , medium load change life N _f2 , small load change life N _f3 and annual average low-cycle fatigue life loss rate e _N , to calculate the main engine of the generating set Low-cycle fatigue remaining life y _rlni of low-pressure rotor, steam drum, steam-water separator, low-temperature header and low-temperature steam pipeline is:

${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; r</span>}\mathrm{<span\; class="notranslate">\; ln</span>}\mathrm{<span\; class="notranslate">\; i</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}<span\; class="notranslate">\; -</span>{\mathrm{<span\; class="notranslate">\; E.</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}$

$<span\; class="notranslate">\; =</span><span\; class="notranslate">\; [</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}<span\; class="notranslate">\; -</span><span\; class="notranslate">\; (</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; c</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fc</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; w</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fw</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; h</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fh</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; r</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fr</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; 1</span>}}}{{\mathrm{<span\; class="notranslate">\; <figure-callout\; id="1"\; label="N\; f"\; filenames="A20071017227900191.png"\; state="\{\{state\}\}">N</figure-callout></span><figure-callout\; id="1"\; label="N\; f"\; filenames="A20071017227900191.png"\; state="\{\{state\}\}">\; </figure-callout>}}_{\mathrm{<span\; class="notranslate">\; </span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; 2</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; f</span>}\mathrm{<span\; class="notranslate">\; 2</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; 3</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; f</span>}\mathrm{<span\; class="notranslate">\; 3</span>}}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; ]</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}$

In the formula, D _Ni is the index value of the total life loss of the important parts of the main engine of the generating set, according to the

According to the experience accumulated in life management of generator sets, the value range of D _Ni is defined as D _Ni =75%-100%;

Step 7: Calculating the remaining creep life y _rlti of important components of the main engine of the unit generating set

The technicians of the client browser in the maintenance department send instructions to the calculation/application server through the web server, and the calculation/application server reads the cumulative working hours τ _j of the required high-temperature components in each temperature range from the database, and uses the calculation/application server Calculate the residual creep of boiler reheater tubes and superheater tubes based on the creep life design value τ _Rj and the annual average creep life loss rate e _ti calculated in advance in the medium life calculation software corresponding to the median values of different temperature ranges The lifetime y _rlti is:

${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; rlti</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; -</span>{\mathrm{<span\; class="notranslate">\; E.</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; -</span><span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}\frac{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; i</span>}}}{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; Rj</span>}}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}$

In the formula, D _ti is the index value of the total creep life loss of the important parts of the main engine of the generating set, according to the

Based on the experience accumulated in life management of generator sets, the value range of D _ti is defined as D _ti =75%-100%;

Step 8: Calculating the remaining life of the important components of the main engine of the generator unit under the joint action of creep and low cycle fatigue Using the existing technology, online calculation of the cumulative low-cycle fatigue life loss E _Ni and cumulative creep life loss of the high-temperature components of the generator set E _ti and the average annual life loss rate e _yi , the remainder of high and medium pressure rotors, high pressure inner cylinders, medium pressure inner cylinders, high pressure main steam valve casings, medium pressure main steam valve casings, high temperature headers, and high temperature pipelines of generator sets Lifetime y _rlnti is:

y _rlnti = (DE _Ni -E _ti )/e _yi

In the formula, D is the index value of the total life loss of the important components of the main engine of the generator set. According to the experience accumulated in the life management of generator sets for many years, D=100% is defined;

Step 9: Calculate the remaining life y _rlnvi of the important components of the main engine of the unit generator set under the joint action of low cycle fatigue and torsional vibration fatigue

Using the existing technology, calculate the cumulative low-cycle fatigue life loss E _Ni of the generator rotor, the cumulative torsional vibration fatigue life loss E _vi and the annual average life loss rate e _zi , the remaining life y _rlnvi of the generator rotor is:

y _rlnvi ＝(DE _Ni -E _vi )/e _zi

Step 10: Calculating the remaining life y _rlai of the important parts of the main engine of the unit generator set under the joint action of corrosion and wear

Read the measured wall thickness δ of the pipe in the database, and use the data designed by the life calculation software in the calculation/application server, including the original wall thickness δ ₀ of the pipe, the original outer diameter of the pipe D ₀ , and the creep limit σ of the steel at the service temperature _c . Pressure P inside the tube, remaining life y _rlai under the action of smoke side corrosion and wear of boiler water wall tubes and economizer tubes

${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; rlai</span>}}<span\; class="notranslate">\; =</span>\frac{\mathrm{<span\; class="notranslate">\; \&delta;</span>}<span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; 2</span>}\mathrm{<span\; class="notranslate">\; \&sigma;</span>}}_{\mathrm{<span\; class="notranslate">\; c</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; P</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; P</span>}<span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; 0</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; 2</span>}{\mathrm{<span\; class="notranslate">\; \&delta;</span>}}_{\mathrm{<span\; class="notranslate">\; 0</span>}}<span\; class="notranslate">\; )</span>}{\mathrm{<span\; class="notranslate">\; v</span>}<span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; 2</span>}\mathrm{<span\; class="notranslate">\; \&sigma;</span>}}_{\mathrm{<span\; class="notranslate">\; c</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; P</span>}<span\; class="notranslate">\; )</span>}$

In the formula, v=(δ ₁ -δ ₀ )/S _h1 , δ ₁ is the wall thickness measured last time, and _Sh1 is the accumulated operating hours between δ ₁ and δ ₀ ;

Step 11: Calculate the remaining insulation life y _rlwi of the important components of the main engine of the generating set

Calculate online the accumulative working hours τ _ej of the winding in each voltage segment and the accumulative operating hours τ _hj in each temperature segment, and use the winding insulation electrical aging life t _ej determined in advance by the life planning software in the calculation/application server corresponding to different voltages And the winding insulation thermal aging life t _hj corresponding to different working temperatures and the annual average insulation aging life loss e _wi , the insulation aging life y _rlwi of the generator stator winding and the main transformer winding is:

${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; rlwi</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; w</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}\frac{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; ej</span>}}}{{\mathrm{<span\; class="notranslate">\; t</span>}}_{\mathrm{<span\; class="notranslate">\; ej</span>}}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}\frac{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; hj</span>}}}{{\mathrm{<span\; class="notranslate">\; t</span>}}_{\mathrm{<span\; class="notranslate">\; hj</span>}}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; wi</span>}}$

In the formula, _Dw is the total life loss of the winding. According to the experience accumulated in the life management of generator sets for many years, _Dw = 100% is defined;

Step 12: Recommend optimal maintenance measures for unit generator sets

According to the prediction results of the remaining life y _rlxi (y _rlni , or y _rlti , or y _rlnti , or y _rlnvi , or y _rlnai , or y _rlnwi ) of the important components of the main engine of the generating set, the optimized maintenance of the main engine of the generating set is recommended in the planned maintenance The measures are:

1. If y _rlxi < 1.5 years, it is recommended to arrange planned maintenance within the year, to be repaired or replaced;

2.1.5 years ≤ y _rlxi < 4.5 years, it is recommended to arrange planned maintenance after 1 year but within 4 years, to be repaired or replaced;

3.4.5 years ≤ y _rlxi < 8.5 years, it is recommended that in the next planned maintenance, detailed flaw detection inspection should be carried out on mechanical parts, and aging identification test should be carried out on winding insulation;

4. y _rlxi ≥ 8.5 years, it is recommended to arrange the planned maintenance cycle and planned maintenance items of the unit generator set according to the power plant's "Guidelines for Equipment Maintenance of Power Generation Enterprises";

Step 13: Print the result

Output and print the online monitoring results of transient life loss d _i and d _v of the main components of the main unit of the unit generator set and the proposed optimization operation suggestions of the unit generator set, as well as the prediction results and recommended optimization of the remaining life y _rlxi of the main components of the unit generator set Maintenance measures.

The present invention has the following characteristics:

The present invention uses the life management system and method given above, and calculates the transient life loss of important components of the unit generator set online based on the unit generator unit on-line monitoring data, operation statistics data, maintenance measurement data and design data, and guides the operation ; On-line calculation of the remaining life of important components of the main engine of the unit generator set to guide equipment maintenance.

The advantage of the present invention is that in the use stage of the unit generating set, a set of life management system is adopted to realize the online calculation and monitoring of the transient life loss and remaining life of multiple important components of the four main engines of the unit generating set. The transient low-cycle fatigue life loss and transient torsional vibration fatigue life loss of important components guide the operation, and the planned maintenance is arranged according to the remaining life of the important components of the main unit of the unit generator set, so that the life of the important components of the main unit of the unit generator set can be kept at The controlled state can not only avoid inappropriate operation and excessive loss of the design life of the important parts of the main unit of the unit unit, but also make full use of the remaining life of the important parts of the main unit of the generator set, and realize the use of life management technology to manage the unit generator set equipment, to achieve the technical effect of not only reducing the life loss of important components of the main engine of the generating set, but also rationally using the remaining life of the important components of the generating set.

Description of drawings

Fig. 1 is the block diagram of important component life management system that the present invention adopts;

Fig. 2 is the flow chart of the method adopted in the life management of the present invention;

Fig. 3 is the computer software block diagram of life management of the present invention;

Figure 4 is a schematic diagram of the remaining life prediction results of the main engine components of the generator set.

Detailed ways

As shown in Figure 1, it is the life management system for important components of the main engine of the steam unit generator set, which consists of life calculation/application server and software 1, database server 2, external system interface 3, data acquisition system DAS of the main engine of the generator set and parameter measurement points 4 , a web server 5 and a client browser 6. The web server 5 is respectively connected to the calculation/application server 1, the database server 2 and the client browser 6, the calculation/application server 1 is connected to the database server 2, and the database server 2 is connected to the data acquisition system and parameters of the generator set main engine through the external system interface 3 Measuring point 4 is connected.

As shown in Figure 2, it is a flow chart of the method provided by the present invention, and as shown in Figure 3, it is a block diagram of the life management computer software for the important parts of the unit generator set main engine written in C language for the present invention, and the software is installed on the main engine of the unit generator set On the calculation/application server of component life management, it is suitable for the life management of different important components of the main engine of the unit generator set.

The present invention will be further described below in conjunction with drawings and embodiments.

Example

For a certain type of supercritical 600MW generator set with an inlet steam temperature of 566°C, the high and medium pressure rotors, high pressure inner cylinders, low pressure rotors, steam-water separators, superheater pipes, superheater high-temperature headers, generator rotors, and generator stator windings Insulation, main transformer winding insulation, using the life management system shown in Figure 1, the flow chart of the method provided by the present invention as shown in Figure 2 and the computer software for life management of important parts of the main engine of the generator set shown in Figure 3, calculated The prediction results of the remaining life of the important components of the main engine of the generator set above are listed in Figure 4.

The first step: every Δτ=3 minutes, store the measuring point parameters of the generator set in the measuring point data of the 600MW steam turbine data acquisition system DAS 4 into the database server 2 through the external system interface 3, these parameters are: the rotating speed of the steam turbine, Unit power, steam pressure before the main steam valve, steam temperature before the main steam valve, steam temperature after the regulating stage, metal temperature of the high pressure inner cylinder at the regulating stage, steam pressure before the main steam valve of the medium pressure, steam temperature before the main steam valve of the medium pressure, Medium pressure inner tank metal temperature, middle exhaust steam pressure or four extraction steam pressure, middle exhaust steam temperature or four extraction steam temperature, medium and low pressure connecting pipe temperature, condenser vacuum; boiler main steam outlet flow, temperature and pressure, boiler The flow rate, temperature and pressure of reheat steam outlet, the flow rate, temperature and pressure of boiler feed water, the flow rate, temperature and pressure of reheat steam inlet, the wall temperature measurement point value of steam drum or steam-water separator, header and pipeline; Active power, three-phase current and voltage, generator shaft torsional vibration signal, working temperature of generator stator winding insulation;

Step 2: Every Δm=1 day, input the accumulative operating hours S _h of the main engine of the 600MW generating set, the accumulative number of cold starts n _c , the accumulative number of warm starts n _w , the accumulative number of hot starts n _h , the accumulative pole The number of hot starts n _r , the cumulative number of large load changes n ₁ , the cumulative number of medium load changes n ₂ , the cumulative number of small load changes n ₃ ; 5. Input the measured wall thickness δ of the pipe into the database server 2;

Step 3: The life evaluation items of the 8 important components of the main engine of the 600MW unit are listed in Table 2

[Table 2]

Step 4: Read the data of the measuring points in the database server 2 online, and use the low-cycle fatigue life management software for multiple components of the main engine of the unit unit to calculate the high and medium pressure rotor, high pressure inner cylinder, low pressure rotor, and steam-water separation of the main engine of the 600MW generator set. Transient low-cycle fatigue life loss d _i or transient torsional vibration fatigue life loss d _v of generator, high-temperature superheater header, and generator rotor are stored in the database server.

Step 5: According to the experience accumulated in years of research on the life management technology of the main engine components of the generator set, define the threshold values [d] and [d _v ] of the low-cycle fatigue life loss of the main engine components of the generator set, which are shown in Table 3;

[table 3]

At a certain moment during a certain load change process of the 600MW generator set, all of these nine components have d _i =<0.8[d], and the optimal operation suggestion is that there is no need to adjust the temperature rise rate of the main steam temperature of the steam turbine and the load increase of the steam turbine rate.

Steps 6 to 11: For the main engine of this type of 600MW unit, the design calendar life and average life loss rate of these nine components are listed in Table 4, and the online calculation results of the remaining life are shown in Table 5 and Figure 4;

[Table 4]

[table 5]

Step 12: After the main engine of the 600MW generating set has been used for 11.5 years, the remaining life of the main transformer winding insulation is at least 6.5 years. According to the test results, the spare parts purchase plan is arranged; the maintenance and treatment measures for other important components of the main engine are to arrange the planned maintenance cycle and planned maintenance items of the unit generator set in accordance with the "Guidelines for Equipment Maintenance of Power Generation Enterprises".

Using the management method and system for the life of important components of the main unit generator set provided by the present invention, the transient life loss and remaining life of the nine important components of the four main engines of the 600MW generating set can be quantitatively calculated online, and the online calculation is based on the transient life loss As a result, the optimization operation suggestion is put forward, and the planned overhaul cycle and planned overhaul items of the main components of the unit generator set are arranged according to the remaining life prediction results, so that the life of nine important components of the four main engines of the 600MW generating set is in a controlled state. According to the life management results of the nine components of the four main engines of the 600MW generating set, the operation control measures and planned maintenance can be taken, which can not only ensure the safe operation of the nine components of the main engine of the 600MW generating set, but also make reasonable use of the remaining life. A set of life management system manages the technical effect of the life of the nine components of the four main engines of the 600MW generating set.

Claims (3)

1. A life management system for important components of a unit generator set main engine, characterized in that it consists of a life calculation/application server and software (1), a database server (2), an external system interface (3), and a generator set main engine data acquisition system DAS is composed of parameter measuring points (4), web server (5) and client browser (6), and web server (5) is connected with calculation/application server (1), database server (2) and client browser ( 6) Connection, the computing/application server (1) is connected to the database server (2), and the database server (2) is connected to the data acquisition system DAS of the main unit of the generating set and the parameter measuring point (4) through the external system interface (3). 2. A life management system for key components of a unit generator set according to claim 1, wherein said parameter measuring points are: the speed of the steam turbine, the unit power, the steam pressure before the main steam valve, the main steam valve Front steam temperature, steam temperature after regulating stage, metal temperature of high pressure inner cylinder at regulating stage, steam pressure before medium pressure main steam valve, steam temperature before medium pressure main steam valve, metal temperature of medium pressure inner cylinder, middle exhaust steam pressure or four Extraction pressure, mid-exhaust steam temperature or four-extraction steam temperature, medium-low pressure connecting pipe temperature, condenser vacuum; boiler main steam outlet flow, temperature and pressure, boiler reheat steam outlet flow, temperature and pressure, boiler feed water Flow rate, temperature and pressure, reheat steam inlet flow rate, temperature and pressure, wall temperature measurement point value of steam drum or steam separator, header and pipeline; active power of generator, three-phase current and voltage, generator shafting Torsional vibration signal, working temperature of generator stator winding insulation. 3. A method for managing the life of important parts of a main unit generator set according to claim 1, characterized in that the calculation software for the life loss and remaining life of the important parts of a unit generator unit main unit written in C language runs in the calculation/ On the application server (1), it is applied to the life management of important components of the main engine of the unit generator set, and the method is as follows: Step 1: Store online monitoring data Through the external system interface (3), the flow, pressure, temperature, speed, power, wall temperature, current, voltage, torque, and The measuring point data such as vibration signal and working temperature are stored in the database server (2); Step 2: Enter basic data Through the user end of the maintenance department, input the cumulative running hours S _h and cumulative cold state The number of starts n _c , the cumulative number of warm starts n _w , the cumulative number of hot starts n _h , the cumulative number of very hot starts n _r , the cumulative number of large load changes n ₁ , the cumulative number of medium load changes n ₂ , the cumulative number of small load changes Number of times n ₃ ; after each scheduled maintenance, the maintenance department enters the measured wall thickness δ of the pipe in the database server (2) through the web server (5) on the client browser (6); Step 3: Determine the life evaluation items of important components of the main engine According to the experience accumulated in the life management of generator sets for many years, the life evaluation items of important components of the defined unit generator set host are shown in Table 1 [Table 1]

Step 4: online calculation of the transient life loss d _i and d _v of important parts of the generator unit main engine is applied to the computer software installed on the computing/application server for the life of the important components of the generator unit main engine, and the prior art is used to calculate the unit generator main engine online Transient low cycle fatigue life loss d _i and transient torsional vibration fatigue life loss d _v of important components; Step 5: Put forward suggestions for optimal operation of unit generator sets The low-cycle fatigue life loss d _i and torsional vibration fatigue life loss d _v calculated online for the important components of the main engine of the generator set are respectively related to the low-cycle fatigue life loss limit value [d] and the torsional vibration fatigue life loss [d _v ] for comparison, if d _i ≤0.8[d], the rate of change of main steam temperature and load change rate of the main engine of the generator set shall operate according to the specified values in the "Operation Regulations for Main Engine of Generator Sets"; if d _v ≤[d _v ], The unit is operating normally. In the case of d _i >0.8[d], the optimization operation suggestions are put forward according to the following four situations: if 0.8[d]<d _i ≤[d], reduce the change rate of main steam temperature and load change rate of the generator set; If [d]<d _i ≤1.05[d], the rate of change of the main steam temperature and the load of the generator set are controlled to be 0; if 1.05[d]<d _i ≤1.25[d], an alarm will be issued, Trip and stop after 1 minute; if d _i > 1.25[d], an alarm will be issued, and trip and stop will be triggered after 1 minute; in the case of d _v > 0.8[d _v ], an alarm will be issued; Step 6: Calculating the remaining low-cycle fatigue life y _rlni of the important components of the main engine of the unit generating set The technical staff of the client browser in the maintenance department sends instructions to the computing/application server (1) through the web server (5), and the computing/application server (1) reads the required cumulative startup times and the cumulative The number of load changes, using the cold start-stop life N _fc , warm start-stop life N _fw , hot start-stop life N _fh , extremely hot start-stop life N _fr , life of large load fluctuations N _f1 , life of medium load fluctuations N _f2 , life of small load fluctuations N _f3 , and annual average low-cycle fatigue life loss rate e _N Low cycle fatigue remaining life y _rlni of steam drum, steam-water separator, low-temperature header and low-temperature steam pipeline is ${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; r</span>}\mathrm{<span\; class="notranslate">\; ln</span>}\mathrm{<span\; class="notranslate">\; i</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}<span\; class="notranslate">\; -</span>{\mathrm{<span\; class="notranslate">\; E.</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}$ $<span\; class="notranslate">\; =</span><span\; class="notranslate">\; [</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}<span\; class="notranslate">\; -</span><span\; class="notranslate">\; (</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; c</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fc</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; w</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fw</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; h</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; f</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; r</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; fr</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; 1</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; f</span>}\mathrm{<span\; class="notranslate">\; 1</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; 2</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; f</span>}\mathrm{<span\; class="notranslate">\; 2</span>}}}<span\; class="notranslate">\; +</span>\frac{{\mathrm{<span\; class="notranslate">\; no</span>}}_{\mathrm{<span\; class="notranslate">\; 3</span>}}}{{\mathrm{<span\; class="notranslate">\; N</span>}}_{\mathrm{<span\; class="notranslate">\; f</span>}\mathrm{<span\; class="notranslate">\; 3</span>}}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; ]</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; Ni</span>}}$ In the formula, D _Ni is the index value of the total life loss of the important parts of the main engine of the generator set. According to the experience accumulated in the life management of generator sets for many years, the value range of D _Ni is defined as D _Ni = 75%-100%; Step 7: Calculating the remaining creep life y _rlti of important components of the main engine of the unit generating set The technicians of the client browser in the maintenance department send instructions to the calculation/application server (1) through the web server (5), and the calculation/application server (1) reads the cumulative working hours of the required high-temperature components in each temperature range from the database τ _j , using the creep life design value τ _Rj calculated in advance in the life calculation software in the calculation/application server (1) corresponding to the median value of different temperature range groups and the annual average creep life loss rate e _ti to calculate the boiler The remaining creep life y _rlti of the reheater tube and the superheater tube is ${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; rlti</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; -</span>{\mathrm{<span\; class="notranslate">\; E.</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}<span\; class="notranslate">\; -</span><span\; class="notranslate">\; (</span>\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}\frac{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; j</span>}}}{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; Rj</span>}}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; \&times;</span>\mathrm{<span\; class="notranslate">\; 100</span>}<span\; class="notranslate">\; \%</span><span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; ti</span>}}$ In the formula, D _ti is the index value of the total creep life loss of the important parts of the main engine of the generator set. According to the experience accumulated in the life management of generator sets for many years, the value range of D _ti is defined as D _ti =75%-100%; Step 8: Calculate the remaining life of the important components of the main engine of the unit generator set under the joint action of creep and low cycle fatigue Using the existing technology, the cumulative low-cycle fatigue life loss E _Ni , the cumulative creep life loss E _ti and the annual average life loss rate e _yi of the high-temperature components of the generator set are calculated online. The remaining service life y _rlnti of inner cylinder, high-pressure main steam valve casing, medium-pressure main steam valve casing, high-temperature header and high-temperature pipeline is y _rlnti = (DE _Ni -E _ti )/e _yi In the formula, D is the index value of the total life loss of the important components of the main engine of the generator set. According to the experience accumulated in the life management of generator sets for many years, D=100% is defined; Step 9: Calculate the remaining life y _rlnvi of the important components of the main engine of the unit generator set under the joint action of low cycle fatigue and torsional vibration fatigue Using the existing technology, calculate the cumulative low-cycle fatigue life loss E _Ni of the generator rotor, the cumulative torsional vibration fatigue life loss E _vi and the annual average life loss rate e _zi , the remaining life of the generator rotor y _rlnvi is y _rlnvi ＝(DE _Ni -E _vi )/e _zi Step 10: Calculating the remaining life y _rlai of the important parts of the main engine of the unit generator set under the joint action of corrosion and wear Read the measured wall thickness δ of the pipe in the database, and use the data designed by the life calculation software in the calculation/application server (1), including the original wall thickness δ ₀ of the pipe, the original outer diameter of the pipe D ₀ , the creep of the steel at the service temperature Variable limit σ _c , pipe internal pressure P, remaining life y _rlai under the action of smoke side corrosion and wear of boiler water wall pipes and economizer pipes is: ${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; rlai</span>}}<span\; class="notranslate">\; =</span>\frac{\mathrm{<span\; class="notranslate">\; \&delta;</span>}<span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; 2</span>}\mathrm{<span\; class="notranslate">\; \&sigma;</span>}}_{\mathrm{<span\; class="notranslate">\; c</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; P</span>}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; P</span>}<span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; 0</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; 2</span>}{\mathrm{<span\; class="notranslate">\; \&delta;</span>}}_{\mathrm{<span\; class="notranslate">\; 0</span>}}<span\; class="notranslate">\; )</span>}{\mathrm{<span\; class="notranslate">\; v</span>}<span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; 2</span>}\mathrm{<span\; class="notranslate">\; \&sigma;</span>}}_{\mathrm{<span\; class="notranslate">\; c</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; P</span>}<span\; class="notranslate">\; )</span>}$ In the formula, v=(δ ₁ -δ ₀ )/S _h1 , δ ₁ is the wall thickness measured last time, and _Sh1 is the accumulated operating hours between δ ₁ and δ ₀ ; Step 11: Calculate the remaining insulation life y _rlwi of the important components of the main engine of the generating set Calculate online the accumulative operating hours τ _ej of the winding in each voltage segment and the accumulative operating hours τ _hj in each temperature segment, using the electrical aging of the winding insulation corresponding to different voltages determined in advance by the life planning software in the calculation/application server (1) The lifetime t _ej and the thermal aging lifetime t _hj of the winding insulation corresponding to different operating temperatures and the annual average insulation aging lifetime loss _ewi , the insulation aging lifetime y _rlwi of the generator stator winding and the main transformer winding are: ${\mathrm{<span\; class="notranslate">\; the\; y</span>}}_{\mathrm{<span\; class="notranslate">\; rlwi</span>}}<span\; class="notranslate">\; =</span><span\; class="notranslate">\; (</span>{\mathrm{<span\; class="notranslate">\; D.</span>}}_{\mathrm{<span\; class="notranslate">\; w</span>}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}\frac{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; ej</span>}}}{{\mathrm{<span\; class="notranslate">\; t</span>}}_{\mathrm{<span\; class="notranslate">\; ej</span>}}}<span\; class="notranslate">\; -</span>\mathrm{<span\; class="notranslate">\; \&Sigma;</span>}\frac{{\mathrm{<span\; class="notranslate">\; \&tau;</span>}}_{\mathrm{<span\; class="notranslate">\; hj</span>}}}{{\mathrm{<span\; class="notranslate">\; t</span>}}_{\mathrm{<span\; class="notranslate">\; hj</span>}}}<span\; class="notranslate">\; )</span><span\; class="notranslate">\; /</span>{\mathrm{<span\; class="notranslate">\; e</span>}}_{\mathrm{<span\; class="notranslate">\; wi</span>}}$ In the formula, _Dw is the total life loss of the winding. According to the experience accumulated in the life management of generator sets for many years, _Dw = 100% is defined; Step 12: Recommend optimal maintenance measures for unit generator sets According to the prediction results of the remaining life y _rlxi (y _rlni , or y _rlti , or y _rlnti , or y _rlnvi , or y _rlnai , or y _rlnwi ) of the important components of the main engine of the generating set, the optimized maintenance of the main engine of the generating set is recommended in the planned maintenance The measures are: 1. If y _rlxi < 1.5 years, it is recommended to arrange planned maintenance within the year, to be repaired or replaced; 2.1.5 years ≤ y _rlxi < 4.5 years, it is recommended to arrange planned maintenance after 1 year but within 4 years, to be repaired or replaced; 3.4.5 years ≤ y _rlxi < 8.5 years, it is recommended that in the next planned maintenance, detailed flaw detection inspection should be carried out on mechanical parts, and aging identification test should be carried out on winding insulation; 4. y _rlxi ≥ 8.5 years, it is recommended to arrange the planned maintenance cycle and planned maintenance items of the unit generator set according to the power plant's "Guidelines for Equipment Maintenance of Power Generation Enterprises"; Step 13: Print the result Output and print the online monitoring results of transient life loss d _i and d _v of the main components of the main unit of the unit generator set and the proposed optimization operation suggestions of the unit generator set, as well as the prediction results and recommended optimization of the remaining life y _rlxi of the main components of the unit generator set Maintenance measures.

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