Digital closed loop proportional hydraulic pressure controller

Abstract

A digitally controlled current to pressure converter (CPC) and method of controlling same is provided. The method of controlling includes the step of periodically imparting symmetrically-opposed movement of a control valve of the CPC to loosen and flush accumulated silt therefrom. More particularly, the method may include the step of periodically introducing a small-amplitude symmetrically-opposed impulse to a controller that actuates a hydraulic control shaft of a three-way rotary valve. Also provided is a method of preventing malfunction due to faulty input or feedback signals received by the CPC, and a method of detecting the health status of multiple CPCs when used in a redundant configuration.

Claims

1. A method comprising the steps of: providing at least two current-to-pressure converters (CPCs) in a positioning control system for valves and actuators; configuring one of the at least two CPCs as a master CPC, and configuring another of the at least two CPCs as a slave CPC, wherein the master CPC controls a hydraulic pressure within the positioning control system; linking the master CPC and slave CPC such that the master CPC knows an operational status of the slave CPC, and the slave CPC knows an operational status of the master CPC; and the slave CPC taking control of the hydraulic pressure within the positioning control system when operational status of the master CPC indicates failure of the master CPC.

2. The method of claim 1, wherein configuring one of the at least two CPCs as a master CPC or as a slave CPC comprises setting an external jumper or relay to establish the master or slave role of the CPC.

3. The method of claim 1, wherein the at least two CPCs will automatically arbitrate a master or slave role if there is no external jumper or relay provided to differentiate the master or slave role of the least two CPCs.

4. The method of claim 1, wherein the slave CPC taking control of the hydraulic pressure within the positioning control system comprises the slave CPC controlling a select valve to switch control of the hydraulic pressure from the master CPC to the slave CPC.

5. The method of claim 1, wherein the slave CPC taking control of the hydraulic pressure within the positioning control system comprises the slave CPC taking control of the hydraulic pressure from the master CPC in less than 20 milliseconds.

6. The method of claim 1, wherein the slave CPC taking control of the hydraulic pressure within the positioning control system comprises the slave CPC taking control of the hydraulic pressure from the master CPC without intervention by an external controller.

7. The method of claim 2, wherein the external jumper or relay is connected between an input of the master CPC and an input of the slave CPC.

8. The method of claim 7, wherein the input of the master CPC and the input of the slave CPC are connected to a CPC supervisory logic.

9. The method of claim 8, wherein the CPC supervisory logic interfaces with a service port via a service port communications module so as to allow for field programming and/or diagnostics of the positioning control system.

10. The method of claim 8, wherein the CPC supervisory logic includes an output for a shutdown relay of the positioning control system.

11. The method of claim 8, wherein the CPC supervisory logic includes an analog output that is capable of driving a control pressure meter.

12. The method of claim 1, wherein the hydraulic pressure within the positioning control system controls a turbine servo system that operably varies a steam control valve.

13. The method of claim 1, wherein the master CPC controls the hydraulic pressure within the positioning control system by determining when additional hydraulic pressure is needed and sourcing hydraulic fluid from a tank.

14. The method of claim 13, wherein the master CPC controls the hydraulic pressure within the positioning control system by determining when less hydraulic fluid is needed and draining hydraulic fluid back to the tank.

15. The method of claim 1, wherein the master CPC is designated initially in the positioning control system by a location of installation within the positioning control system relative to the slave CPC.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:

(2) FIG. 1 is a simplified system level diagram of a typical installation of an embodiment of a CPC constructed in accordance with the teachings of the present invention;

(3) FIG. 2 is a cross-sectional illustration of an embodiment of a CPC constructed in accordance with the present invention;

(4) FIG. 3 is a hydraulic schematic of the CPC of FIG. 2;

(5) FIG. 4 is a simplified CPC controller block diagram illustrating one embodiment of a controlled constructed in accordance with the teachings of the present invention;

(6) FIG. 5 is simplified system level diagram of a master/slave CPC installation constructed in accordance with the teachings of the present invention;

(7) FIG. 6 is a simplified block diagram illustrating the redundancy switch over logic utilized in an embodiment to the present invention for redundant control inputs;

(8) FIG. 7 is a simplified block diagram illustrating the redundancy switch over logic utilized in an embodiment to the present invention for redundant transducer feedback;

(9) FIG. 8 is a graphical illustration of the output pressure verses command input available from one embodiment of the present invention;

(10) FIG. 9 is a graphical illustration of the symmetrical anti-silting impulse function effectuated by one embodiment to the present invention; and

(11) FIG. 10 is a graphical illustration of a single symmetrical anti-silting impulse event utilized in one embodiment of the present invention.

(12) While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

(13) Turning now to the drawings, and specifically to FIG. 1, there is illustrated a typical turbine control system 100 to which embodiments of the present invention are particularly well suited. However, while the following description will utilize this exemplarity installation of an embodiment of a CPC 102 constructed in accordance with the teachings of the present invention, this installation is not meant to be limiting, but will aid in the understanding of the functionality and advantages provided by such a CPC 102. Other installations and operations of embodiments of the present invention will be recognized by those skilled in the art from the following description, and application thereof are specifically reserved.

(14) In such an installation as illustrated in FIG. 1, the CPC 102 may interface with a turbine controller 104, such as a Model 505/505E Steam Turbine Digital Controller available from the assignee of the instant invention. Such a turbine controller 104 is typically microprocessor-based and is designed to operate steam turbines 106, such as, e.g. single extraction and/or admission steam turbines. Embodiments of the CPC 102 may also interface with a system plant controller 108 to provide, for example, feedback information from the CPC 102 as well as fault information.

(15) In operation, the CPC 102 receives command signals from the turbine controller 104 in the form of an analog control signal varying between 4 and 20 mA. The control logic within the CPC 102 processes this control command signal and either increases or decreases the hydraulic pressure to the turbine's servo system 110. The servo system 110 is operable to vary a steam control valve 112 to vary the operating speed of the steam turbine 106. In the system illustrated in FIG. 1, the steam turbine 106 is used to drive a load, such as a pump 114, a generator (not shown), etc. As will be discussed more fully below, when the CPC 102 determines that additional hydraulic pressure is needed, it sources hydraulic fluid from tank 116 via pump 118 and filter 120 to the servo system 110. When the CPC 102 determines that less hydraulic pressure is needed, the CPC operates to drain hydraulic fluid back to tank 116.

(16) To effectuate such operational control, the CPC 102 includes digital control mounted internal to the housing 122 on a digital electronic assembly (referred to hereinafter as a digital printed circuit board (PCB) 124) as may be seen in FIG. 2. This digital PCB 124 is protected by a PCB cover 126 and may be accessed by removing the access cover 128 which meets with the housing 122 to form a sealed enclosure.

(17) The controller mounted on this digital PCB 124 controls the position of the hydraulic control shaft 130 via a rotary limited angle torque (LAT) actuator 132. Specifically, the LAT 132 includes a permanent magnet rotor 134 that is directly coupled to the hydraulic control shaft 130. The position of the rotor 134 is measured by a solid state integrated circuit on the digital PCB 124 which detects the direction of the sensing magnet 136 on the hydraulic control shaft 130. The H-bridge drive of the LAT 132 is regulated by the microprocessor on the digital PCB 124 to control the position of the hydraulic control shaft precisely to maintain the pressure set point received from the turbine controller 104.

(18) The hydraulic control shaft 130 rotates within a hydraulic control bushing 138 that is ported to form a three-way rotary valve 140. This three-way rotary valve 140 controls the hydraulic fluid flow from the supply (not shown) to the control port 142 and from the control port 142 to the drain (not shown). In a preferred embodiment, both the hydraulic control shaft 130 and the hydraulic control bushing 138 are made of stainless steel. This offers precise, reliable, and contamination-tolerant operation on typical oils used for steam turbine lubrication.

(19) To provide failsafe operation in the event of component or power failure, a spiral power spring 144 operates the bottom portion of the hydraulic control shaft 130 in the lower cavity 146 of the housing 122. Access to the spiral power spring 144 is via lower cover 148. In the event of power failure, the spiral power spring 144 will provide sufficient rotary power to rotate the hydraulic control shaft 130 into a failsafe condition. One embodiment of this failsafe condition couples the control port 142 with the drain.

(20) To protect the dry stator 150 a redundant dynamic sealing system 152 is utilized. This redundant dynamic sealing system 152 includes an intermediate passage 154 to the hydraulic drain circuit. This ensures that the pressure drop across the outboard seal 156 is very low, minimizing the potential for leakage and improving the reliability of the CPC 102.

(21) Precise hydraulic pressure control is aided by the inclusion of a pressure transducer 158 that provides the microprocessor with a precise indication of the current hydraulic pressure supplied via control port 142. This on-board pressure transducer 148 improves the linearity and accuracy of the closed loop control of the output pressure over prior CPC's that utilized a force feedback device.

(22) The simplified hydraulic schematic of FIG. 3 provides an illustration of the operational connection of the hydraulic control circuit within the CPC 102. As may be seen, the digital PCB 124 provides a position control signal to the LAT 132 to position the three-way rotary valve 140. Position feedback for the closed loop control is provided by the sensing magnet 136. As discussed briefly above, the 3-way rotary valve 140 is designed to couple the control port 142 with either the supply port 160 or the drain port 162 to control the pressure, sensed by pressure transducer 158, to the servo system 110 in accordance with the control signal received from the turbine controller 104 (see FIG. 1).

(23) As may be seen from this hydraulic schematic of FIG. 3, when the 3-way rotary valve 140 is in the mid position, the control port 142 is coupled to neither the supply port 160 nor the drain port 162. In this configuration, the output hydraulic pressure is held constant at control port 142. If the pressure drops below the set point pressure, the PCB 124 will command the LAT 132 to rotate the valve such that control port 142 is connected to the supply port 160 to increase the pressure in the control port 142 (as sensed by pressure transducer 158). If, however the hydraulic pressure at the control port 142 is higher than desired, the control circuitry on the PCB 124 will command the LAT 132 to position the 3-way rotary valve 140 so as to couple the control port 142 to the drain port 162 to lower the pressure at the control port 142.

(24) This dynamic pressure control is controlled by a digital control algorithm 164 executed within the digital PCB 124, such as that illustrated in simplified block diagram form in FIG. 4, to which reference is now made. As may be seen from the simplified block diagram, the digital controller 164 may include a control demand input 166 and, in one embodiment, a redundant control demand input 168. This or each of these inputs are passed through signal conditioners 170. The control logic for dealing with two controlled demand inputs will be discussed more fully below. Once this control demand input is determined, it is used in a pressure proportional integral derivative (PID) control loop 172. As illustrated, this PID control loop 172 receives a control oil pressure feedback from pressure transducer 158 and a feedback position signal from the sensing magnet 136 (not shown). Based on this information, the digital controller 164 controls the position of the valve 140 via the LAT 132.

(25) The digital controller 164 also includes in an embodiment a service port 174 that interfaces with the CPC supervisory logic 176 via a service port communications module 178. This service port allows, for example, field programming and diagnostics via a PC or microprocessor-based service tool. The CPC supervisory logic 176 monitors the operation of the CPC and includes outputs for a shutdown relay 180, an alarm relay or red unit status 182, a master slave indication 184 where such functionality is provided (see description below regarding FIG. 5), and/or analog output 186 that is capable of driving, for example, a control pressure meter 188.

(26) In the embodiments of the CPC 102 of the present invention that are utilized in a master/slave environment such as that shown in FIG. 5, the CPC supervisory logic 176 also includes master/slave inputs 190. These master/slave inputs 190 may be utilized with external jumpers or relays to establish an initial role for the particular CPC based on installation location. However, even in systems that utilize initial role designations, the CPC supervisory logic 176 includes logic to facilitate control transfer between CPCs upon the detection of a fault of a master or other conditions that may necessitate or make desirable such control transfer.

(27) As illustrated in FIG. 4, the master indication output 184 includes two status lines that connect to the other CPC(s). The CPC supervisory logic 176 in each CPC 102 monitors these lines. If either CPC 102 fails, or if the signal line fails, the other CPC will take control within a prescribed period of time, i.e. 10 milliseconds. This minimizes any transition bump to the servo system 110 which can occur with prior CPC's wherein such delay between switching to a new CPC control upon the failure of the master may be 100 milliseconds or more depending upon the computing rate of the main controller. As will be recognized by those skilled in the art, such a long transition time may result in a very large control pressure transient and corresponding changes in speed or load of the controlled plant.

(28) A simplified single line illustration of a system 100 utilizing a slave CPC 102A and associated slave turbine controller 104A in addition to the master CPC 102B and associated master turbine controller 104B is shown in FIG. 5. As discussed above, control of the hydraulic pressure to the servo system 110 is provided by the master CPC 102B until a fault is detected therewith. Upon determination that the master CPC 102B has failed, the select valve 210 switches hydraulic pressure control to the slave CPC 102A. In an embodiment of the present invention, the two CPCs 102A/102B have a status link 212 wired directly from the master indication circuit 184 (see FIG. 4) of one CPC 102A to the other CPC 102B. As such, each CPC 102A/102B knows the operational status of the other CPC 102B/102A. Should a fault occur within the master CPC 102B in control of the system 100, the back-up unit or slave CPC 102A can assume control in an extremely short time interval without intervention from the main turbine or plant controller. This minimizes the potential for dynamic transitions which could adversely affect the speed or load of the turbine 106.

(29) FIG. 6 illustrates a functional block diagram of the redundancy switch over logic 196 utilized in embodiments of the present invention that include multiple control inputs 166, 168. Specifically, each control input 166, 168 is monitored by input diagnostics 192, 194 to evaluation the reasonableness of the values on each of the two control inputs 166, 168. If the input diagnostics 192, 194 determines that one of the input signals 166, 168 is considered faulty, e.g., out of range, unstable, etc., it will be voted out of the chain by the redundancy switch over logic 196 and the CPC 102 will continue to operate only based on the non-faulty input. If the redundancy switch over logic 196 determines that both signals are faulty, then the CPC is commanded to a failsafe position and an appropriate alarm or other indication is provided. If both input signals are considered valid, although different, the redundancy switch over logic 196 may simply select one of the two inputs for control, may average the two inputs, take the higher, the lower, or other input logic processing to provide the operating setpoint signal for the CPC 102.

(30) Similar redundancy switch over logic 198 may be utilized along with feedback signal diagnostics 200, 202 to evaluate the reasonableness of multiple feedback signals 204, 206 in embodiments that utilize multiple feedbacks, e.g., multiple feedback transducers, position sensors, etc. This feedback redundancy switch over logic 198 is illustrated in FIG. 7.

(31) As illustrated in FIG. 8, the digital controller 164 provides multiple adjustments that greatly increase the type of installations and functionality within each installation of the CPC 102 of the present invention. As shown in the output pressure versus command input scaling graphical illustration of FIG. 8, an adjustment can be made of the minimum pressure level and the maximum pressure level. The minimum pressure level adjustment sets the level of output pressure. Adjusting the minimum pressure level changes all points of the output pressure uniformly. That is, adjusting the minimum level sets the minimum travel of the servo system 110 (see FIG. 1). The maximum pressure level adjustment sets the maximum output pressure when the output command control signal is at 20 milliamps. Increasing this level increases the slope of the line 208 and the position of the output servo system for each value of the input signal.

(32) The PID control loop 172 settings may also be adjusted to tune the dynamic performance of the CPC 102. The proportional gain may be adjusted to set the amount of gain (proportional action). In one embodiment ten percent gain is used. As will be recognized by those skilled in the art, a high gain provides a fast response time, but can cause instability. The integral gain may also be adjusted to set the stability (integration action) of the PID control loop 172. This stability cooperates with the proportional gain setting to provide stable operation. Finally, a derivative component of the PID control loop 172 may also be adjusted to set the amplitude of the output dither.

(33) As discussed above, failures of CPC's in installations that utilize redundant or backup CPC's or in systems that do not vary the hydraulic output for extended periods of time have been determined to be a result of the accumulation of fine silting particles. These failures are particularly acute in steam turbine applications such as that shown in FIG. 1 wherein the turbine's lubricating oil is used as the hydraulic control fluid. To overcome this problem, an embodiment of the CPC 102 of the present invention include a symmetrical anti-silting impulse function as part of its control logic. Specifically, the digital controller 164 includes an algorithm which introduces a small amplitude, symmetrically opposed, impulse on the position of the three-way rotary valve 140. This small impulse will cause a rotation of the three-way rotary valve 140 very slightly in both directions.

(34) As illustrated in FIG. 9, these impulses may occur at fixed or periodic times. The selection of the interval may be set or varied based upon the particular installation and the amount of silt and contamination typically associated therein. These small impulses are effective in loosening and flushing away any silt that has accumulated on the valve element during the period of inactivity. The plot of FIG. 9 shows an impulse interval set at five hours. However, this interval may be manually or automatically varied within the CPC 102.

(35) In one embodiment the automatic variation of the anti-silting impulse is based upon a detection of a deviation in the driver current levels needed to effectuate movement of the three-way rotary valve 140. Increased driver current requirements are an indication of the build-up of contamination on the valve. When such a condition is detected, the frequency of anti-silting impulses may be increased. Similarly, if the driver current is not sensed as being at a level that might indicate contamination build-up on the valving element, the anti-silting interval may be extended so as to prolong the life of the internal bearings and seals.

(36) As illustrated in FIG. 10, each anti-silting impulse event is of very short duration and very low amplitude. Indeed, the use of the digital controller 164 allows adjustment of various parameters controlling the anti-silting impulse, such as the amplitude, frequency, and duration thereof. With regard to the amplitude of the anti-silting impulse, typically a one percent impulse is sufficient to flush contaminants from the CPC 102. However, this may be adjusted as required to achieve the anti-silting benefit within the parameters of the system performance. In one embodiment amplitudes up to five percent can be set either at the factory or in the field via the service tool interface discussed above. The frequency of the anti-silting impulse may also be adjusted as discussed above. While FIG. 9 illustrated an interval of five hours, other embodiments may utilize the impulse only once per day, although other installations may require impulses generated at a frequency from, for example, one minute to three months. This interval may also be set at the factory or in the field. Finally, the duration of each anti-silting impulse may also be varied. Depending on overall system performance issues, durations from four milliseconds to one hundred milliseconds may be utilized, with a typical duration of forty milliseconds being sufficient to loosen the silt without causing undue motion of the servo mechanism 110. However, longer or shorter durations may be set as required or desired.

(37) All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

(38) The use of the terms a and an and the and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms comprising, having, including, and containing are to be construed as open-ended terms (i.e., meaning including, but not limited to,) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., such as) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

(39) Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.