Patent Grant
11814964
The present inventions relate generally to valves, and more particularly, to controlling the position of a valve.
Electrical power plants employ large steam turbines to generate electricity. In a steam turbine, a main steam valve is used to control the flow rate of steam to the turbine. Thus, accurate valve position is important for efficient and safe operation of a steam turbine. The inventions disclosed herein may also be used to control the position of other valves as well.
The invention may be more fully understood by reading the following description in conjunction with the drawings, in which:
One aspect of the preferred embodiments is the use of relays (Solid State Relays “SSRs”) that make/break connections to field I/O devices. For a redundant pair, only the module acting as the primary module activates its relays, which allow the same field devices to be connected to both modules. Preferably, redundant field devices are allowed to concurrently connect to both (redundant) valve positioners. Additionally, a single termination unit may be used, thus eliminating the need for two termination units. By contrast, other valve positioners may use separate devices for the individual modules in the redundant pair.
A LVDT (Linear Variable Differential Transformer) is shown in
One feature of the preferred embodiments includes using the SSRs to isolate the drivers of the redundant modules. Another feature is the inter-module communication between the primary and the backup modules. Another feature is the ability of both modules to be connected to the same devices, so they measure the same values.
A redundant LVDT primary oscillation diagram is shown in
A redundant servo coil driver diagram is shown in
One improvement associated with the preferred embodiments includes the isolation of drivers to isolate the redundant modules. Another improvement includes the ability to connect to the same I/O devices and requiring only a single termination unit. Another improvement includes the inter-module communication to accomplish fast and bumpless transfer.
A principal application for the preferred embodiments is generally large steam turbines at electrical power plants. In this application, the control system interfaces with main steam valves requiring redundant valve positioners. Furthermore, other smaller machines may also require similar redundancy, and the control system may be used in other systems requiring redundant valve controllers.
A problem overcome by the preferred embodiments is the elimination of the need to provide separate devices for the individual modules in a redundant pair. The preferred embodiments allow for the redundant field devices to concurrently connect to both (redundant) valve positioners. Moreover, a single termination unit may be connected to eliminate the need for additional hardware.
One advantage of the preferred embodiments is that redundant field devices can concurrently connect to a redundant pair of valve positioners. Another advantage is that the field device can connect to a single termination unit. Another advantage is eliminating the need for additional hardware. Another advantage is allowing for a nearly seamless transfer of coil drivers upon failover.
In the preferred embodiments, the module has redundant Solid State Relays (SSRs) that interface with the redundant field devices. Initially, the primary module activates the SSRs connecting the module to the I/O, while the backup module deactivates its SSRs to the I/O. The redundant pair of modules communicate with each other via a communication bus. Each module provides the status of its hardware and operating condition. The primary module informs the backup of the operating condition so the backup can take over control upon failover from the primary to the backup. Upon failover the primary deactivates its SSRs while the backup activates its SSRs. This transfer may occur in less than 1 millisecond allowing for a nearly seamless transfer. Since the backup (now primary) has operating conditions from the other module it can take control immediately. Furthermore, each module informs the controller of its status, so the operator becomes aware of a failed module to allow time to replace the failed module. This can be done on-line so there is no interruption of the operation of the system.
Preferably, the system includes two redundant valve positioners. Each of the valve positioners may be housed in a separate hardware module. The valve positioner modules may be plugged into one or more termination units, which provide an interface between the valve positioner modules and the field devices. The termination unit may also be thought of as a backplane of the system. Preferably, both of the redundant field devices are connected to both of the valve positioners. As described, two redundant valve positioners are also preferably provided with each valve positioner module including SSRs to control which valve positioner is connected to the field devices. The field devices sense and/or control the valves.
Another aspect of the preferred embodiments is a cascaded PI (proportional integral) control loop that may be used for a non-mechanically linked servo valve. The control loop utilizes two feedback devices to form a closed-loop control system. One of the feedback devices reports the position of the pilot valve section of the valve. The other feedback device reports the position of the main hydraulic valve section of the valve. The two sections form a cascaded process.
Unlike the typical process control employed for a non-mechanically linked valve that utilizes an inner/outer loop strategy (cascade control), the preferred embodiments resolve the errors of both parts of the process within a single control process. Moreover, the inner/outer loop strategy is typically implemented using separate processors operating on different modules, which often leads to difficulty in getting the operation to settle without oscillation due to the time lag in communication between the two processors and the different transfer rates of the two parts of the process. Preferably, the control of the preferred embodiments resides wholly within a single processor, which eliminates the problems caused by time lag that is inherent with the inner/outer loop strategy. Also, the preferred embodiments employ a weighting factor that is applied to the main valve error in order to compensate for the difference in transfer ratios between the two parts of the process.
In order to hold the main hydraulic valve section steady, the pilot valve must be held at its midpoint, referred to as the bias position. The value of the Pilot Valve Bias Position parameter sets the bias position.
The difference between the bias position and the pilot valve position yields an error value. The difference between the demand value and the main hydraulic valve position yields another error value. The two error values are used to generate a current output to move the valve. The control algorithm ramps the output current up and down in order to produce smooth movement of the valve. The control algorithm contains elements that prevent the condition commonly referred to as “integral windup” from having an impact on the control operation.
Because the two sections of this valve have different process transfer rates, one of the valve errors is multiplied by the value of the Weight Gain parameter to balance the control process. The error that has the weight gain applied to it is selected by the Weight Gain Application parameter.
The values of the Proportional Gain and Integral Factor parameters establish the rate of movement, and how quickly the control loop settles out.
The equation used in the PI algorithm has the form shown below, where E is the position error, O is the coil drive output, and A1 and A0 are coefficients derived from the values of P and I.
Ok+1=A1·Ek+1+A0·Ek+Ok
The preferred embodiments use one of the equations shown below to compute the position error, where E is the position error, D is the main hydraulic valve position demand, Rm is the reported main hydraulic valve position, B is the pilot valve bias position, Rp is the reported pilot valve position, and W is the value of the Weight Gain parameter. The equation that is used depends on the value of the Weight Gain Application parameter.
E=(D−Rm)·W+(B−Rp), Weight Gain Application=0
E=(D−Rm)+(B−Rp)·W, Weight Gain Application=1
The values of the coefficients are set by the equations shown below, where P is the proportional gain, I is the integral factor, and Ts is the sample time.
To utilize a P only control loop, set the value of the Integral Factor parameter to 0. The value of A0 may be set to 0 in the preferred embodiments. The equation used in the control loop may be reduced to the form shown below.
Ok+l=P·Ek+1+Ok
The control algorithm will not allow the value of O to become greater than the maximum coil current, as selected by the DIP switch. When a request is made for the preferred embodiments to move the valve away from a stop position, the system clears the old output value to counter the effects of integral windup, and thus there is no delay in valve movement.
An exemplary control algorithm is shown in
A principal application for the preferred embodiments is generally large steam turbines at electrical power plants. In this application, the control system interfaces with a main steam valve controlled by a pilot valve. Furthermore, the control system may also be used on other smaller machines.
A problem overcome by the preferred embodiments is the need to control the position of a servo valve actuator that utilizes a two phase cascaded control process, each with its own position indicating transducer and each with its own transfer function. Another problem overcome by the preferred embodiments is that control must be stable and fast responding, while providing for a user friendly and intuitive method to balance out the two control loops to achieve optimal control. The preferred embodiments also address the physical constraints and configuration requirements of various implementations of this type of actuator with a single solution. The preferred embodiments also improve upon hardware solutions designed to control one specific implementation of this type of actuator. These solutions are specific to one actuator and are not readily configurable or tunable for either the setting of the PID values or the compensation for the rate difference of the transfer functions. The preferred embodiments also improve upon the utilization of two individual controllers to control the operation of each phase of the cascaded process separately, using an inner loop/outer loop interaction between them. These solutions can prove difficult to implement due to the timing constraints built into the required interaction between the two phases.
One advantage of the preferred embodiments is that soft configuration of the PID settings provides the flexibility to apply this solution to various implementations of this type of actuator. Another advantage is that soft configuration of the PID settings provides the ability to tune the operation of the control functionality. Another advantage is that soft configuration of the compensation for the rate difference of the transfer functions provides the flexibility to apply this solution to various implementations of this type of actuator. Another advantage is that the solution may be provided via a single module.
The preferred embodiments provide configurable parameters built into the software control algorithm to provide on-the-fly adjustment of the control configuration so that it may be used to control any implementation of this type of actuator. The solution provided by the preferred embodiments may be contained within a single module, so that it is not necessary to use multiple modules with tight timing characteristics between them.
The position of the pilot valve may be controlled by the bias demand. The position of the pilot valve controls oil flow to the main valve (or steam valve) to control the position of the main valve. The position demand for the main valve is the desired set value for the main valve. Thus, in order to achieve the desired set value for the main valve, the bias demand must be controlled.
The inventions as described herein may have one or more of the following features in addition to any of the features described above. Referring to the figures, the following features are shown.
A system for redundant valve positioning including a mechanical valve positioner 10 connected to a turbine valve 12 to open and close the turbine valve 12, the mechanical valve positioner 10 comprising a first coil 14A, 16A and a second coil 14B, 16B to control or sense movement of the mechanical valve positioner 10; a first valve positioner 18 comprising a first drive circuit 20A, 22A and a second drive circuit 20B, 22B, the first drive circuit 20A, 22A comprising a first driver 24, 26 and a first switch 28, and the second drive circuit 20B, 22B comprising a second driver 24, 26 and a second switch 28, the first drive circuit 20A, 22A being in communication the first coil 14A, 16A and the second drive circuit 20B, 22B being in communication with the second coil 14B, 16B; a second valve positioner 30 comprising a third drive circuit 20A, 22A and a fourth drive circuit 20B, 22B, the third drive circuit 20A, 22A comprising a third driver 24, 26 and a third switch 28, and the fourth drive circuit 20B, 22B comprising a fourth driver 24, 26 and a fourth switch 28, the third drive circuit 20A, 22A being in communication the first coil 14A, 16A and the fourth drive circuit 20B, 22B being in communication with the second coil 14B, 16B; wherein only one of the first switch 28 and the third switch 28 is closed at a time, the first driver 24, 26 and the third driver 24, 26 thereby being alternately connected to the first coil 14A, 16A at different times such that the first driver 24, 26 and the third driver 24, 26 do not drive the first coil 14A, 16A at a same time; and wherein only one of the second switch 28 and the fourth switch 28 is closed at a time, the second driver 24, 26 and the fourth driver 24, 26 thereby being alternately connected to the second coil 14B, 16B at different times such that the second driver 24, 26 and the fourth driver 24, 26 do not drive the second coil 14B, 16B at a same time.
The system for redundant valve positioning wherein the first coil 14A, 16A and the second coil 14B, 16B are redundant coils.
The system for redundant valve positioning wherein the first coil 14A and the second coil 14B are redundant position sensing coils 14A, 14B.
The system for redundant valve positioning wherein the first coil 14A and the second coil 14B are each a primary coil 32 in a respective first linear variable differential transformer (LVDT) 34 and a second linear variable differential transformer (LVDT) 34, the first LVDT 34 and the second LVDT 34 being redundant LVDTs.
The system for redundant valve positioning wherein the first LVDT 34 comprises a first secondary coil 36 outputting a first position signal 38 and the second LVDT 34 comprises a second secondary coil 36 outputting a second position signal 38, the first secondary coil 36 and the second secondary coil 36 both being in communication with the first valve positioner 18 and the second valve positioner 30 such that the first valve positioner 18 and the second valve positioner 30 both receive the first position signal 38 and the second valve position signal 38.
The system for redundant valve positioning wherein the communications between the first secondary coil 36, the second secondary coil 36, the first valve positioner 18 and the second valve positioner 30 are non-switched such that the first valve positioner 18 and the second valve positioner 30 both receive the first position signal 38 and the second position signal 38 at a same time.
The system for redundant valve positioning wherein the first coil 16A and the second coil 16B are redundant servo positioning coils 16A, 16B.
The system for redundant valve positioning wherein the first valve positioner 18 and the second valve positioner 30 share a termination unit 40 which interfaces with the first coil 14A, 16A and the second coil 14B, 16B.
The system for redundant valve positioning wherein a first field wire 42 connects the first coil 14A, 16A to the termination unit 40 and a second field wire 42 connects the second coil 14B, 16B to the termination unit 40, the first drive circuit 20A, 22A and the third drive circuit 20A, 22A both communicating with the first coil 14A, 16A through the first field wire 42 and the second drive circuit 20B, 22B and the fourth drive circuit 20B, 22B both communicating with the second coil 14B, 16B through the second field wire 42.
The system for redundant valve positioning wherein the first valve positioner 18 and the second valve positioner 30 are separate hardware modules.
The system for redundant valve positioning wherein the first valve positioner 18 comprises a first circuit board 44 and the second valve positioner 30 comprises a second circuit board 44, the first drive circuit 20A, 22A and the second drive circuit 20B, 22B being incorporated into the first circuit board 44, and the third drive circuit 20A, 22A and the fourth drive circuit 20B, 22B being incorporated into the second circuit board 44.
The system for redundant valve positioning further comprising a base 46 with a first communications connector 48 and a second communications connector 48, wherein the first valve positioner 18 is connected to the first communications connector 48 and the second valve positioner 30 is connected to the second communications connector 48, the first valve positioner 18 and the second valve positioner 30 communicating directly with each other through the base 46 to control the first switch 28, the second switch 28, the third switch 28 and the fourth switch 28.
The system for redundant valve positioning wherein the base 46 further comprises a third communications connector 50, the first valve positioner 18 and the second valve positioner 30 being in communication with a controller 52 through the third communications connector 50.
The system for redundant valve positioning wherein the first valve positioner 18 is a primary module 18 and the second valve positioner 30 is a backup module 30, the first switch 28 and the second switch 28 being closed and the third switch 28 and the fourth switch 28 being open during normal operation, and upon a failure of the first valve positioner 18 at least the first switch 28 is opened and the third switch 28 is closed to transfer control or sensing from the primary module 18 to the backup module 30.
The system for redundant valve positioning wherein the first switch 28, the second switch 28, the third switch 28 and the fourth switch 28 are each a solid state relay 28.
The system for redundant valve positioning wherein the mechanical valve positioner 10 further comprises a third coil 16A and a fourth coil 16B, the first coil 14A and the second coil 14B being redundant position sensing coils, and the third coil 16A and the fourth coil 16B being redundant servo positioning coils; the first valve positioner 18 further comprising a fifth drive circuit 22A and a sixth drive circuit 22B, the fifth drive circuit 22A comprising a fifth driver 26 and a fifth switch 28, and the sixth drive circuit 22B comprising a sixth driver 26 and a sixth switch 28, the fifth drive circuit 22A being in communication the third coil 16A and the sixth drive circuit 22B being in communication with the fourth coil 16B; the second valve positioner 30 further comprising a seventh drive circuit 22A and an eighth drive circuit 22B, the seventh drive circuit 22A comprising a seventh driver 26 and a seventh switch 28, and the eighth drive circuit 22B comprising an eighth driver 26 and an eighth switch 28, the seventh drive circuit 22A being in communication the third coil 16A and the eighth drive circuit 22B being in communication with the fourth coil 16B; wherein only one of the fifth switch 28 and the seventh switch 28 is closed at a time, the fifth driver 26 and the seventh driver 26 thereby being alternately connected to the third coil 16A at different times such that the fifth driver 26 and the seventh driver 26 do not drive the third coil 16A at a same time; and wherein only one of the sixth switch 28 and the eighth switch 28 is closed at a time, the sixth driver 26 and the eighth driver 26 thereby being alternately connected to the fourth coil 16B at different times such that the sixth driver 26 and the eighth driver 26 do not drive the fourth coil 16B at a same time.
The system for redundant valve positioning wherein the first coil 14A and the second coil 14B are each a primary coil 32 in a respective first linear variable differential transformer (LVDT) 34 and a second linear variable differential transformer (LVDT) 34, the first LVDT 34 and the second LVDT 34 being redundant LVDTs, the first LVDT 34 comprises a first secondary coil 36 outputting a first position signal 38 and the second LVDT 34 comprises a second secondary coil 36 outputting a second position signal 38, the first secondary coil 36 and the second secondary coil 36 both being in communication with the first valve positioner 18 and the second valve positioner 30 such that the first valve positioner 18 and the second valve positioner 30 both receive the first position signal 38 and the second valve position signal 38, and the communications between the first secondary coil 36, the second secondary coil 36, the first valve positioner 18 and the second valve positioner 30 are non-switched such that the first valve positioner 18 and the second valve positioner 30 both receive the first position signal 38 and the second position signal 38 at a same time.
The system for redundant valve positioning wherein the first valve positioner 18 and the second valve positioner 30 share a termination unit 40 which interfaces with the first coil 14A, the second coil 14B, the third coil 16A and the fourth coil 16B, and a first field wire 42 connects the first coil 14A to the termination unit 40, a second field wire 42 connects the second coil 14B to the termination unit 40, a third field wire 42 connects the third coil 16A to the termination unit 40 and a fourth field wire 42 connects the fourth coil 16B to the termination unit 40, the first drive circuit 20A and the third drive circuit 20A both communicating with the first coil 14A through the first field wire 42, the second drive circuit 20B and the fourth drive circuit 20B both communicating with the second coil 14B through the second field wire 42, the fifth drive circuit 22A and the seventh drive circuit 22A both communicating with the third coil 16A through the third field wire 42 and the sixth drive circuit 22B and the eighth drive circuit 22B both communicating with the fourth coil 16B through the fourth field wire 42.
The system for redundant valve positioning wherein the first valve positioner 18 and the second valve positioner 30 are separate hardware modules, the first valve positioner 18 comprises a first circuit board 44 and the second valve positioner 30 comprises a second circuit board 44, the first drive circuit 20A, the second drive circuit 20B, the fifth drive circuit 22A and the sixth drive circuit 22B being incorporated into the first circuit board 44, and the third drive circuit 20A, the fourth drive circuit 20B, the seventh drive circuit 22A and the eighth drive circuit 22B being incorporated into the second circuit board 44, further comprising a base 46 with a first communications connector 48 and a second communications connector 48, wherein the first valve positioner 18 is connected to the first communications connector 48 and the second valve positioner 30 is connected to the second communications connector 48, the first valve positioner 18 and the second valve positioner 30 communicating directly with each other through the base 46 to control the first switch 28, the second switch 28, the third switch 28, the fourth switch 28, the fifth switch 28, the sixth switch 28, the seventh switch 28 and the eighth switch 28, and wherein the base 46 further comprises a third communications connector 50, the first valve positioner 18 and the second valve positioner 30 being in communication with a controller 52 through the third communications connector 50.
A system for controlling a turbine valve 60 including a hydraulic pilot valve section 62 being moveable in a first direction 64 from a middle position 66 and moveable in a second direction 68 from the middle position 66 opposite from the first direction 64; a main hydraulic valve section 70 being moveable in a first direction 72 to close the turbine valve 60 when the hydraulic pilot valve section 62 is moved in the first direction 64 and moveable in a second direction 74 to open the turbine valve 60 when the hydraulic pilot valve section 62 is moved in the second direction 68; a position demand 76 indicating a desired position of the turbine valve 60; a first feedback 78 indicating an actual position of the hydraulic pilot valve section 62; a second feedback 80 indicating an actual position of the main hydraulic valve section 70; a pilot valve error 82 determined by a difference 84 between the middle position 66 of the hydraulic pilot valve section 62 and the first feedback 78; a main valve error 86 determined by a difference 88 between the position demand 76 and the second feedback 80; a turbine valve error 88 determined by combining 90 the pilot valve error 82 and the main valve error 86; and a pilot valve adjustment 92 moving the hydraulic pilot valve section 62 in response to the turbine valve error 88; wherein the turbine valve error 88 is repeatedly determined and the pilot valve adjustment 92 repeatedly moves the hydraulic pilot valve section 62 to minimize the turbine valve error 88.
The system for controlling a turbine valve wherein the turbine valve 60 is a steam valve 60.
The system for controlling a turbine valve further comprising a weight gain 94 applied to the pilot valve error 82 or the main valve error 86.
The system for controlling a turbine valve wherein the weight gain 94 applies a greater weight to the pilot valve error 82.
The system for controlling a turbine valve wherein the turbine valve error 88 further incorporates a proportional gain 96 and an integral factor 98.
It is understood that the preferred embodiments described herein may be implemented as computerized methods in a non-transitory computer readable medium if desired.
While preferred embodiments of the inventions have been described, it should be understood that the inventions are not so limited, and modifications may be made without departing from the inventions herein. While each embodiment described herein may refer only to certain features and may not specifically refer to every feature described with respect to other embodiments, it should be recognized that the features described herein are interchangeable unless described otherwise, even where no reference is made to a specific feature. It should also be understood that the advantages described above are not necessarily the only advantages of the inventions, and it is not necessarily expected that all of the described advantages will be achieved with every embodiment of the inventions. The scope of the inventions is defined by the appended claims, and all devices and methods that come within the meaning of the claims, either literally or by equivalence, are intended to be embraced therein.
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