百万千瓦超超临界机组的精细状态监测、故障诊断与自愈调控关键技术研究

项目来源

国家自然科学基金(NSFC)

项目主持人

赵春晖

项目受资助机构

浙江大学

立项年度

2017

立项时间

未公开

项目编号

U1709211

研究期限

未知 / 未知

项目级别

国家级

受资助金额

200.00万元

学科

信息科学-自动化-控制理论与技术

学科代码

F-F03-F0301

基金类别

联合基金项目-重点支持项目-NSFC-浙江两化融合联合基金

关键词

全工况 ; 精细状态监测 ; 故障诊断 ; 故障自愈 ; 故障预测 ; full operation conditions ; detailed condition monitoring ; fault diagnosis ; fault prognosis ; fault self-recovery

参与者

刘向杰;王印松;谢尉扬;胡伯勇;孔小兵;张淑美;张震伟;唐晓宇;余万科

参与机构

华北电力大学;浙江浙能技术研究院有限公司

项目标书摘要:大容量、高参数、低能耗的百万千瓦超超临界机组是发电领域的高端装备,已成为浙江省乃至全国电力工业发展的主流方向,其安全可靠运行对推动浙江省两化深度融合和发电企业转型升级具有重要意义。本项目在系统分析机组全流程复杂特性和深度变负荷动态过渡特性基础上,提取高端装备运行状态监控与故障诊断的关键科学问题,建立一整套面向百万千瓦超超临界机组全工况的运行状态监控与故障诊断的理论方法和关键技术,包括:提出一种能适应不同稳定工况和动态过渡工况的全工况精细化状态监测方法;提出一种变负荷动态运行和多故障并发条件下的智能故障诊断以及缓变故障预测方法;提出一种非优状态的优化补偿策略和基于自愈知识库与全局优化的故障自修复策略。在上述理论方法研究的基础上,形成面向百万千瓦超超临界机组的高端工业自动化技术,并在浙江省浙能集团下属电厂百万千瓦超超临界机组上进行示范应用,提高设备透明化水平和运行效率,进一步推动智能电厂发展。

Application Abstract: 1000MW ultra supercritical unit with large capacity,high parameter and low energy consumption is the high-end equipment in power generation and has become the main development direction of the power industry in both Zhejiang province and China.Its safe and reliable operation has been of great significance to the integration of information technology and industrialization in Zhejiang province and upgrading of power plant.Based on a systematic analysis of the plant-wide complexity and dynamic transition characteristics under varying load conditions,this project will reveal the key scientific problems of condition monitoring and fault diagnosis for high-end equipment and develop a set of theoretical methods and key technologies of conditions monitoring and fault diagnosis for 1000MW ultra supercritical unit under full operation conditions.It includes a detailed full condition monitoring method for different steady conditions and dynamic transition conditions,an intelligent diagnosis and slow-varying fault prognostic method for varying load conditions and multiple faults,and an optimal compensation strategy for non-optimal state and fault self-recovery strategy based on knowledge base and global optimization.Finally,the proposed advanced industrial automation technology will be demonstrated on the real 1000MW ultra supercritical unit in Zhejiang province to improve the unit operation efficiency and promote the development of smart power plant.

项目受资助省

浙江省

项目结题报告(全文)

大容量、高参数、低能耗的百万千瓦超超临界机组是发电领域的重大装备,其安全可靠运行对推动两化深度融合和发电企业转型升级具有重要意义。本项目在系统分析机组全流程复杂特性和深度变负荷动态过渡特性基础上,建立了大范围非平稳运行工况智能监控基础理论,攻克了大范围非平稳变化下运行工况难以精准识别的技术瓶颈,研发的监控系统在多家电厂进行了示范应用,提高了设备透明化水平和运行效率。在国际国内期刊及重要国际国内会议上发表/录用论文97篇,包括SCI论文69篇,EI收录等28篇(与SCI不重复统计)。研究成果发表于IEEE TCYB、IEEE TIP、IEEE TCST、IEEE TNNLS、IEEE TIE等权威IEEE汇刊30余篇、IFAC过程控制顶刊JPC等,以及自动化学报等国内核心期刊。10余篇论文先后入选ESI高被引论文(2篇为热点论文)。先后多次获得国际国内权威学术会议的最佳论文奖或提名奖(一作或通讯)。出版专著3本,获中国石油和化学工业优秀出版物奖:图书奖一等奖1项。授权国家发明专利35项、软件著作权2项,已形成了对重大发电装备运行工况智能监控的专利保护族群。研究工作获中国自动化学会自然科学一等奖、浙江省首届青年科技英才奖、中国石化工业联合会科技进步(图书)三等奖等科技奖励。项目负责人获得了国家杰出青年科学基金的资助,获浙江省青年拔尖人才、中国过程控制青年奖等荣誉奖励。培养国家青年基金获得者5人,培养的博士获中国自动化学会优博提名、中国电子学会优博等。受邀担任6家国内外期刊编委,其中IFAC过控领域顶刊JPC目前全球仅设有5名高级编委(Senior Editor),赵春晖为史上唯一华人高级编委。多次在国内外学术会议作大会报告及特邀报告,其中,IFAC ADCHEM是在全球范围内召开的每三年一次的重要国际会议(全球过程控制领域顶级会议),赵春晖受邀做大会报告。成果已在集团下属嘉华和台二电厂形成示范应用,部分实现高端工业监控软件的国产化替代,仅软件维护费用一项,每年可减少470万元以上。与原有监控软件相比,解决了误报率高的问题,在不增加漏报的前提下,误报率降低60%;典型故障溯源的准确率高于90%。因此,设备潜在风险能够被及时处理,避免更大安全事故,为机组的稳定安全运行提供了有力的技术保障。

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  • 1.Non-stationary data reorganization for weighted wind turbine icing monitoring with Gaussian mixture model

    • 关键词:
    • Monitoring;Wind turbines;Gaussian distribution;Electric power generation;Wind power;Data reorganization;Gaussian Mixture Model;Indicator variables;Non stationary characteristics;Nonstationary process;Partition algorithms;Posterior probability;Process characteristics
    • Jing, Hua;Zhao, Chunhui;Gao, Furong
    • 《Computers and Chemical Engineering》
    • 2021年
    • 147卷
    • 期刊

    The ice accretion on blades is a serious problem affecting the working performance of the wind turbine. Due to the non-stationary characteristic of the wind turbine, the fault information of icing can usually be buried in the normal change of wind power generation process, which makes the icing monitoring a challenging task. In this paper, a novel data reorganization for weighted wind turbine icing monitoring method is developed to handle this problem. Specifically, a novel condition driven analysis concept to replace the traditional time-driven methods is proposed for the non-stationary wind power generation process. The data can be divided into multiple wind speed slices (WSSs), i.e., condition slices, by cutting indicator variable into multiple equal intervals, where each condition slice can characterize certain characteristics for the concerned operating condition. Subsequently, by evaluating the similarity of WSSs, different wind speed modes (WSMs) are revealed by a step-wise sequential condition partition algorithm. In this way, the process characteristics can be similar within the same WSM while quite different for different WSMs. Further, the distribution of each WSM is then evaluated by Gaussian mixture model and weighted monitoring method is designed by weighting the monitoring statistics with the posterior probabilities of each monitored sample belonging to different Gaussian components. Two real data sets are used to validate the effectiveness of the proposed method. In comparison with other methods, comprehensive results illustrate that the proposed method can transform the non-stationary process into different WSMs, and closely describe the process variations, based on which the accurate icing monitoring results can be achieved.
    © 2021 Elsevier Ltd

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  • 2.Fault-Prototypical Adapted Network for Cross-Domain Industrial Intelligent Diagnosis

    • 关键词:
    • Fault diagnosis; Prototypes; Convolutional neural networks; Featureextraction; Employee welfare; Training; Task analysis; Cross-domainfault diagnosis; deep representation learning; fault prototypes;transfer learning
    • Chai, Zheng;Zhao, Chunhui
    • 《IEEE TRANSACTIONS ON AUTOMATION SCIENCE AND ENGINEERING》
    • 2021年
    • 19卷
    • 4期
    • 期刊

    Despite rapid advances in machine learning based fault diagnosis, their identical distribution assumption of the training (source domain) and testing data (target domain) is generally challenged in industrial applications due to the variation of working conditions. In this article, a fault-prototypical adapted network (FPAN) is proposed, which enables cross-domain industrial intelligent fault diagnosis aided by deep transfer learning. First, a similarity learning-based discrimination module is designed to learn fault prototypes (FPs) that are representative for each fault and discriminative across different faults. Then, a fault prototypical-adaptation module is developed, which adapts the multiple FPs to the target dataset and enables more precise category-wise domain invariance. The two modules are trained simultaneously to extract transferrable and discriminative FPs, by which the cross-domain intelligent diagnosis can be readily achieved. Experimental results on two industrial cases illustrate that the proposed approach learns transferable feature representations that better reduce domain discrepancy, and provides improved diagnosis performance on target data.

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  • 3.Variational Progressive-Transfer Network for Soft Sensing of Multirate Industrial Processes

    • 关键词:
    • Data models; Transfer learning; Analytical models; Task analysis;Probabilistic logic; Adaptation models; Uncertainty; Deep learning;multirate industrial processes; progressive transfer learning; softsensor;QUALITY PREDICTION; SENSOR; SUBJECT
    • Chai, Zheng;Zhao, Chunhui;Huang, Biao
    • 《IEEE TRANSACTIONS ON CYBERNETICS》
    • 2021年
    • 期刊

    Deep-learning-based soft sensors have been extensively developed for predicting key quality or performance variables in industrial processes. However, most approaches assume that data are uniformly sampled while the multiple variables are often acquired at different rates in practical processes. This article designed a progressive transfer strategy, based on which a variational progressive-transfer network (VPTN) method is proposed for the soft sensor development of industrial multirate processes. In VPTN, the multirate data are first separated into multiple data chunks where the variables within each chunk are acquired at a uniform rate. Then, a variational multichunk data modeling framework is developed to model the multiple chunks in a unified fashion through deep variational structures. The base models, including the unsupervised ones with only partial process variables and the supervised soft sensor model share a similar network structure, such that the subsequent transfer strategy can be readily implemented. Finally, a progressive transfer learning strategy is designed to transfer the model parameters from the fastest sampled data chunk to the slowest one in a progressive manner. Thus, the knowledge from various data chunks can be sequentially explored and transferred to enhance the performance of the terminal soft sensor model. Case studies on both a debutanizer column dataset and a real coal mill dataset in a thermal power plant validate the performance of the proposed method.

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  • 4.A Deep Probabilistic Transfer Learning Framework for Soft Sensor Modeling With Missing Data

    • 关键词:
    • Probabilistic logic; Data models; Feature extraction; Training; Sensors;Adaptation models; Transfer learning; Deep learning; industrialprocesses; missing data; probabilistic transfer learning (TL); softsensor
    • Chai, Zheng;Zhao, Chunhui;Huang, Biao;Chen, Hongtian
    • 《IEEE TRANSACTIONS ON NEURAL NETWORKS AND LEARNING SYSTEMS》
    • 2021年
    • 33卷
    • 12期
    • 期刊

    Soft sensors have been extensively developed and applied in the process industry. One of the main challenges of the data-driven soft sensors is the lack of labeled data and the need to absorb the knowledge from a related source operating condition to enhance the soft sensing performance on the target application. This article introduces deep transfer learning to soft sensor modeling and proposes a deep probabilistic transfer regression (DPTR) framework. In DPTR, a deep generative regression model is first developed to learn Gaussian latent feature representations and model the regression relationship under the stochastic gradient variational Bayes framework. Then, a probabilistic latent space transfer strategy is designed to reduce the discrepancy between the source and target latent features such that the knowledge from the source data can be explored and transferred to enhance the target soft sensor performance. Besides, considering the missing values in the process data in the target operating condition, the DPTR is further extended to handle the missing data problem utilizing the strong generation and reconstruction capability of the deep generative model. The effectiveness of the proposed method is validated through an industrial multiphase flow process.

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  • 5.FIGAN: A Missing Industrial Data Imputation Method Customized for Soft Sensor Application

    • 关键词:
    • Soft sensors; Data models; Generative adversarial networks; Generators;Training; Task analysis; Probabilistic logic; Industrial process; dataimputation; soft sensor; generative adversarial network; semi-supervisedlearning;DENOISING AUTOENCODER
    • Yao, Zoujing;Zhao, Chunhui
    • 《IEEE TRANSACTIONS ON AUTOMATION SCIENCE AND ENGINEERING》
    • 2021年
    • 19卷
    • 4期
    • 期刊

    Missing data is quite common in the industrial field, resulting in problems in downstream applications, as most data driven methods used in these applications rely on complete and high-quality dataset to build a high-quality model. Existing methods deal with missing data individually regardless of its downstream application, treating all variables equally without considering their different roles in the downstream application. This would affect imputation performance for key variables, thus deteriorating the accuracy of the downstream model. A considerable challenge is how to refine the missing data imputation task. In this paper, a new method termed fine-tuned imputation GAN (FIGAN) is designed to achieve customized data imputation for industrial soft sensor. The major contribution of the paper lies in two aspects: 1) different from the original imputation GAN (GAIN) which treats all variables equally, FIGAN is guided by a soft sensor module so as to achieve customized data imputation by performing improved data imputation on quality-related variables. Enhanced accuracy for the final industrial soft sensor would be possible; 2) in addition, since labels of the soft sensor might also have missing data, a soft sensor with pseudo labeling is designed to conquer the problem with data imputation and label prediction being optimized interactively. Case studies on a converter steelmaking process and a penicillin fermentation process show the feasibility of the proposed FIGAN. It is noted that such customized imputation could be readily transferred to other downstream applications with missing data.

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  • 6.Retrospective comparison of several typical linear dynamic latent variable models for industrial process monitoring

    • 关键词:
    • Retrospective study; Process monitoring; Process dynamics; Dynamiclatent variable (DLV) models; Three-phase flow process;SLOW FEATURE ANALYSIS; PROCESS FAULT-DETECTION; PRINCIPAL COMPONENTANALYSIS; BLIND SOURCE SEPARATION; TIME-SERIES; MULTIVARIATE PROCESSES;CANONICAL CORRELATION; QUANTITATIVE MODEL; FEATURE ANALYTICS;SOFT-SENSOR
    • Zheng, Jiale;Zhao, Chunhui;Gao, Furong
    • 《COMPUTERS & CHEMICAL ENGINEERING》
    • 2022年
    • 157卷
    • 期刊

    Process dynamic behaviors resulting from closed-loop control and the inherence of processes are ubiquitous in industrial processes and bring a considerable challenge for process monitoring. Many methods have been developed for dynamic process monitoring, of which the dynamic latent variables (DLV) model is one of the most practical and promising branches. This paper provides a timely retrospective study of typical methods to fill the void in the systematic analysis of DLV methods for dynamic process monitoring. First, several classical DLV methods are briefly reviewed from three aspects, including original ideas, the determination of parameters, and offline statistics design. Second, a discussion on the relationships of the discussed methods has been established to make a clear understanding of process dynamics explained by each method. Third, five cases of a three-phase flow process are provided to illustrate the effectiveness of the methods from the application viewpoint. Finally, future research directions on dynamic process monitoring have also been provided. The primary objective of this paper is to summarize the prevalent DLV methods for dynamic process monitoring and thus highlight a valuable reference for further improvement on DLV models and the selection of algorithms in practical applications. (C) 2021 Elsevier Ltd. All rights reserved.

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  • 7.Multisource-Refined Transfer Network for Industrial Fault Diagnosis Under Domain and Category Inconsistencies

    • 关键词:
    • Fault diagnosis; Feature extraction; Transfer learning; Task analysis;Training; Employee welfare; Measurement; Deep learning; domain andcategory inconsistencies; fault diagnosis; multisource transfer learning
    • Chai, Zheng;Zhao, Chunhui;Huang, Biao
    • 《IEEE TRANSACTIONS ON CYBERNETICS》
    • 2021年
    • 52卷
    • 9期
    • 期刊

    Unsupervised cross-domain fault diagnosis has been actively researched in recent years. It learns transferable features that reduce distribution inconsistency between source and target domains without target supervision. Most of the existing cross-domain fault diagnosis approaches are developed based on the consistency assumption of the source and target fault category sets. This assumption, however, is generally challenged in practice, as different working conditions can have different fault category sets. To solve the fault diagnosis problem under both domain and category inconsistencies, a multisource-refined transfer network is proposed in this article. First, a multisource-domain-refined adversarial adaptation strategy is designed to reduce the refined categorywise distribution inconsistency within each source-target domain pair. It avoids the negative transfer trap caused by conventional global-domainwise-forced alignments. Then, a multiple classifier complementation module is developed by complementing and transferring the source classifiers to the target domain to leverage different diagnostic knowledge existing in various sources. Different classifiers are complemented by the similarity scores produced by the adaptation module, and the complemented smooth predictions are used to guide the refined adaptation. Thus, the refined adversarial adaptation and the classifier complementation can benefit from each other in the training stage, yielding target-faults-discriminative and domain-refined-indistinguishable feature representations. Extensive experiments on two cases demonstrate the superiority of the proposed method when domain and category inconsistencies coexist.

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  • 8.Bias-Eliminated Semantic Refinement for Any-Shot Learning

    • 关键词:
    • Semantics; Training; Task analysis; Visualization; Generators;Generative adversarial networks; Feature extraction; Any-shot learning;zero-shot learning; semantic representation; feature generation; modalalignment
    • Feng, Liangjun;Zhao, Chunhui;Li, Xi
    • 《IEEE TRANSACTIONS ON IMAGE PROCESSING》
    • 2022年
    • 31卷
    • 期刊

    When training samples are scarce, the semantic embedding technique, i. e., describing class labels with attributes, provides a condition to generate visual features for unseen objects by transferring the knowledge from seen objects. However, semantic descriptions are usually obtained in an external paradigm, such as manual annotation, resulting in weak consistency between descriptions and visual features. In this paper, we refine the coarse-grained semantic description for any-shot learning tasks, i. e., zero-shot learning (ZSL), generalized zero-shot learning (GZSL), and few-shot learning (FSL). A new model, namely, the semantic refinement Wasserstein generative adversarial network (SRWGAN) model, is designed with the proposed multihead representation and hierarchical alignment techniques. Unlike conventional methods, semantic refinement is performed with the aim of identifying a bias-eliminated condition for disjoint-class feature generation and is applicable in both inductive and transductive settings. We extensively evaluate model performance on six benchmark datasets and observe state-of-the-art results for any-shot learning; e. g., we obtain 70.2% harmonic accuracy for the Caltech UCSD Birds (CUB) dataset and 82.2% harmonic accuracy for the Oxford Flowers (FLO) dataset in the standard GZSL setting. Various visualizations are also provided to show the bias-eliminated generation of SRWGAN. Our code is available.(1)

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  • 9.非线性快速批次过程高效迭代学习预测函数控制

    • 关键词:
    • 轨迹线性化;预测函数控制;迭代学习控制;快速非线性批次过程;计算复杂度
    • 马乐乐;刘向杰
    • 《自动化学报》
    • 2022年
    • 02期
    • 期刊

    迭代学习模型预测控制(Iterative learning model predictive control, ILMPC)具备较强的批次学习能力及突出的时域跟踪性能,在批次过程控制中发挥了重要作用.然而对于具有强非线性的快动态批次过程,传统的迭代学习模型预测控制很难实现计算效率与跟踪精度之间的平衡,这给其应用带来了挑战.对此本文提出一种高效迭代学习预测函数控制策略,将原非线性系统沿参考轨迹线性化得到二维跟踪误差预测模型,并在控制器设计中补偿所产生的线性化误差,构造优化目标函数为真实跟踪误差的上界.为加强优化计算效率,在时域上结合预测函数控制以降低待优化变量维数,从而有效降低计算负担.结合终端约束集理论,分析了迭代学习预测函数控制的时域稳定性及迭代收敛性.通过对无人车和典型快速间歇反应器的仿真实验验证所提出算法的有效性.

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  • 10.基于时空依赖性自适应模糊嵌入的交通流量预测方法

    • 关键词:
    • 智能交通;交通流量预测;空间依赖性;模糊嵌入
    • 李其青;竺堃;李宝学;赵春晖
    • 《控制工程》
    • 2024年
    • 期刊

    近年来,建模传感器之间的空间依赖性已经成为实现准确交通流量预测的关键步骤。然而,交通流状态的动态演化对空间依赖性的捕捉造成挑战。具体而言,受各种外部因素的影响,交通流量随着时间的推移会在不同的状态之间动态演化和转换,并可能处于某些重叠状态,从而导致时空依赖性的不确定性。为此,提出了一种时空依赖性自适应模糊嵌入的方法,该方法不通过确定性的状态,而是通过包含多个模糊状态的隶属度向量来刻画交通流量,从而充分表征交通流量的状态演化以及潜在的重叠状态。具体来说,为交通流量构建多个模糊状态,并生成相应的隶属度值来描述交通流量隶属于各种模糊状态的程度,从而可以通过隶属度向量来有效刻画交通流量的动态演化和可能存在的重叠状态,进而准确地感知空间依赖性。此外,为了防止模糊嵌入数据出现模式坍塌问题,设计了一种状态多样性约束来保证所有模糊状态之间的差异性,以提升其表征能力。最后,设计了一种全局-局部时间平滑性约束,以促进模糊状态的演化连续性。在真实公开的交通流量数据集中,所提出的模糊嵌入方法展现出更佳的预测性能,具有较强的工程实践意义。

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