Condition-based monitoring systems, methods, and apparatuses

Patent metadata

Field	Value
Publication number	US-11828805-B2
Application number	US-202117319412-A
Country	US
Kind code	B2
Filing date	May 13, 2021
Priority date	May 13, 2021
Publication date	Nov 28, 2023
Grant date	Nov 28, 2023

Abstract

A condition-based monitoring system receives a plurality of measurements from sensors measuring mechanical and electrical aspects of a prime mover and a synchronous machine. The condition-based monitoring system determines a correlation between the mechanical measurements and electrical measurements to estimate parameters of the model. The condition-based monitoring system also updates the model as sensors obtain additional measurements during operation of the prime mover.

First claim

What is claimed is:

1. A condition-based monitoring system to monitor a power generation system, the system comprising:
a first set of sensors to obtain a plurality of mechanical measurements of a prime mover of the power generation system while the prime mover is in operation the prime mover providing mechanical energy to a synchronous machine;
a second set of sensors to obtain a plurality of electrical measurements of the synchronous machine of the power generation system while the prime mover is in operation, the synchronous machine to convert the mechanical energy to electrical energy;
a data storage device configured to store model data characterizing a model of the prime mover and the synchronous machine; and
processing circuitry to:
receive the plurality of mechanical measurements and the plurality of electrical measurements, including electrical power, frequency, and shaft speed measurements;
calculate torque using the electrical power, frequency, and a rate of change of rotations per minute using the shaft speed measurements;
determine a correlation between one or more of the plurality of mechanical measurements and one or more of the plurality of electrical measurements;
estimate parameters of the model based on the correlation and the calculated torque;
generate the model using the estimated parameters; and
continually update the model as the first set of sensors and the second set of sensors obtain additional measurements during operation of the prime mover

wherein the torque is calculated as:

T
m

=

T
m

=

P
e

f

-

H
⁢
Δ
⁢

δ
˙

where:
T m represents torque,
P e represents electrical power,
f represents frequency,
H represents inertia, and
Δ {dot over (δ)} represents a change of rotations per minute.

2. The condition-based monitoring system of claim 1 , wherein the processing circuitry is further to:
identify a deviation between a correlated mechanical measurement and electrical measurement and the model; and
provide a maintenance indicator based on the deviation.

3. The condition-based monitoring system of claim 2 , wherein the first set of sensors measure a fuel usage, and the second set of sensors measure electrical power output by the prime mover;
wherein to identify the deviation, the processing circuitry uses the model to compare a historical relationship between the fuel valve position and the electrical power output by the prime mover to a present relationship between the fuel valve position and the electrical power output by the prime mover;
wherein when the deviation is identified, the maintenance indicator identifies one or more of fuel British thermal unit (BTU) discrepancy, valve wear, and valve actuator wear.

4. The condition-based monitoring system of claim 2 , further comprising:
a third sensor; and
a fourth sensor;
wherein the first set of sensors measure shaft speed, the second set of sensors measure stator voltage, the third sensor measures field voltage, and the fourth sensor measures field current;
wherein to identify the deviation, the processing circuitry uses the model to compare a historical relationship between the stator voltage and one or more of the shaft speed, field voltage, and field current to a present relationship between the stator voltage and one or more of the shaft speed, field voltage, and field current; and
wherein when the deviation is identified, the maintenance indicator identifies one or more of a turn-to-turn fault, insulation degradation, shaft alignment issue, and rectifier issue.

5. The condition-based monitoring system of claim 2 , further comprising:
a third set of sensors; and
a fourth set of sensors,
wherein the first set of sensors measure shaft speed and shaft position, the second set of sensors measure terminal voltage and current, the third set of sensors measure mechanical vibration, and the fourth set of sensors measure acoustic signals,
wherein the processing circuitry is further to:
perform analysis on data from the third set of sensors and fourth set of sensors to extract key parameters which are then correlated with shaft speed and operating power to build a model by which expected vibration and acoustic parameters can be calculated from shaft speed and power level; and
identify a deviation of measured values from the model, the maintenance indicator identifies one or more of degraded bearing condition, degraded lubrication, machine imbalance, exhaust gas leakage, fuel flow restrictions, exhaust flow restrictions, among other problems.

6. The condition-based monitoring system of claim 2 , further comprising:
a third sensor; and
a fourth sensor;
wherein the first set of sensors measure coolant temperature, the second set of sensors measure electrical power output by the prime mover, the third sensor measures shaft speed, and the fourth sensor measures ambient temperature;
wherein to identify the deviation, the processing circuitry uses the model to compare a historical relationship between the coolant temperature and one or more of the electrical power output by the prime mover, the shaft speed, and the ambient temperature to a present relationship between the coolant temperature and one or more of the electrical power output by the prime mover, the shaft speed, and the ambient temperature; and
wherein when the deviation is identified, the maintenance indicator identifies one or more of an air obstruction, a coolant issue, a winding resistance issue, and an operating outside of elevation envelope issue.

7. The condition-based monitoring system of claim 2 , further comprising:
a third sensor;
wherein the first set of sensors measure shaft speed, the second set of sensors measure electrical power output by the synchronous machine, and the third sensor measures mechanical power of the prime mover;
wherein to identify the deviation, the processing circuitry uses the model to compare a historical relationship between the shaft speed and a difference between the electrical power and the mechanical power to a present relationship between the shaft speed and a difference between the electrical power and the mechanical power; and
wherein when the deviation is identified, the maintenance indicator identifies one or more of a change to rotor inertia, a change to system inertia, and an error in shaft speed measurements.

8. The condition-based monitoring system of claim 2 , further comprising an interface to transmit the maintenance indicator to a protection system.

9. The condition-based monitoring system of claim 1 , wherein the parameters comprise correlation curves between the plurality of mechanical measurements and the plurality of electrical measurements.

10. The condition-based monitoring system of claim 1 , wherein the processing circuitry is further to maintain a table of correlated measurements.

11. The condition-based monitoring system of claim 1 , wherein the model is a state space model relating the plurality of mechanical measurements and t

Assignees

• Schweitzer Engineering Lab Inc

Inventors

• Manson Scott M
• Blood Ellery A
• Zweigle Gregary C

Classifications

• G01R31/343 Primary

  in operation · CPC title

• G01R31/346

  Testing of armature or field windings · CPC title

• H02P9/008

  wherein the generator is controlled by the requirements of the prime mover · CPC title

• H02P6/34

  Modelling or simulation for control purposes · CPC title