JP3624939B2 - Plant operating device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a plant operating apparatus that is applied to the operation of a chemical plant, a steel plant, etc. and that performs the operation according to a predetermined procedure. More specifically, the present invention relates to a plant operation apparatus that has been devised to support improvement in operation efficiency.
[0002]
[Prior art]
In plant operation, unsteady operations represented by startup, shutdown, grade change, etc., treatments for process abnormalities, equipment abnormalities, control abnormalities, etc. that occur during steady operation, control auxiliary operations, etc. are still mainly manual operations. This is an operation area that is often performed. For this reason, driving quality unevenness (control instability, operating time loss, product quality loss, utility loss, lost work, etc.) may occur due to differences in operator skills, and this may become a bottleneck for improving driving efficiency. . Here, the utility loss is a loss of electricity, gas, steam or the like supplied to the plant.
[0003]
In addition, due to the recent labor saving, the number of skilled operators is decreasing rapidly, and it is an urgent task to pass on the operation know-how.
However, since the above-described operation area mainly operated by manual operation largely depends on the operation know-how of the skilled operator, there are the following problems in the conventional automation method using DCS (Distributed Control System) or process computer.
[0004]
(1) Decrease in the degree of completion of the application program is unavoidable when the specifications are transmitted between the operator, the instrumentation engineer, and the manufacturer.
{Circle around (2)} By repeatedly changing and improving the process and operation method, the application program becomes obsolete, and a great deal of labor and cost are required to restore the original degree of completion.
(3) Much effort is required for operations such as interviews with operators, in-house meetings, meetings with manufacturers, and creation of functional specifications. For this reason, it is difficult to continuously evolve and develop application programs.
[0005]
These are due to the fact that there is no automation support system that allows an experienced operator to directly and easily operate from application program development to maintenance. For this reason, rapid system development has been desired by each user.
[0006]
Moreover, in the conventional plant operation apparatus, there was no thing which displayed the operation procedure on the screen. For this reason, the operation know-how of skilled operators is difficult to be passed on to new operators, and the difference in operation quality is large.
[0007]
[Problems to be solved by the invention]
The present invention has been made to solve the above-mentioned problems. An operation efficiency improvement cycle comprising five functions of planning, construction, operation, research, and improvement is prepared, and these five functions are sequentially arranged. By implementing it, the objective is to realize a plant operating device that can maintain and improve the operating efficiency reliably and continuously, and can prevent the application program from becoming obsolete due to changes or improvements in the process or operating method. .
Further, according to the present invention, a skilled operator can easily create a work procedure diagram by connecting icons on the screen, and at the same time, a program for executing the created work procedure diagram is also created. The objective is to realize a plant operating system that can transfer operation know-how to new operators and make operation quality uniform.
[0008]
[Means for Solving the Problems]
The present invention is a plant operation apparatus configured as follows.
[0009]
(1) In a plant operation apparatus that performs plant operation according to a predetermined procedure, based on the data obtained by plant operation, quantitatively find an operation region in which operation efficiency is expected to be improved by automation in the plant operation. Planning function section to support
Prepare each work to be performed in plant operation as a process part icon, select the prepared process part icon and arrange it on the screen according to the operation procedure, and create a work procedure diagram and create an application program for the work procedure diagram A construction function unit to
An operation function unit that executes the application program created by this construction function unit to operate the plant,
A research function to help evaluate application programs after driving and highlight improvements,
An improvement function section that improves the application program based on the improvements highlighted in this research function section,
The plant operation apparatus characterized by repeating the process of the planning function unit, the construction function unit, the operation function unit, the research function unit, and the improvement function unit as a cycle.
[0010]
(2) In a plant operating apparatus that executes plant operation according to a predetermined procedure,
An icon memory prepared by associating icons representing each work performed in plant operation with a ready-made program for executing processing of this icon,
Icon connection means for selecting an icon from the icon memory, connecting the selected icon on the screen, and creating a work procedure diagram showing the work procedure of the plant operation on the screen;
Information generating means for generating information for executing the work procedure created by the icon connecting means;
Based on the information generated by the information generating means and the program associated with the icon in the work procedure diagram, an operation execution unit that executes the plant operation according to the work procedure diagram displayed on the screen,
A plant operation apparatus characterized by comprising:
[0011]
(3) The plant operation apparatus according to (2), wherein the work procedure diagram is a flowchart.
[0012]
(4) The plant operation according to (2), further comprising an input unit for designating an icon in the work procedure diagram displayed on the screen, wherein the operation execution unit performs the operation of the icon designated by the input unit. apparatus.
[0013]
(5) In a plant operation apparatus that executes plant operation according to a predetermined procedure,
An icon memory prepared by associating an icon indicating exception processing with a ready-made program that executes processing of this icon,
Icon connection means for connecting an icon prepared in the icon memory on the screen when an exception process occurs, and creating a work procedure diagram of the exception process on the screen;
Information generating means for generating information for executing the exception handling work procedure created by the icon connecting means;
Based on the information generated by this information generating means and the program associated with the icon in the work procedure diagram, exception processing execution means for executing the plant operation of exception processing according to the work procedure diagram of exception processing,
A plant operation apparatus characterized by comprising:
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the drawings.
FIG. 1 is a block diagram showing an embodiment of the present invention.
The plant operation apparatus includes a planning function unit 1, a construction function unit 2, an operation function unit 3, a research function unit 4, and an improvement function unit 5. An operation efficiency improvement cycle is formed by sequentially executing the processing of the five functional units.
FIG. 2 is a conceptual diagram of an operation efficiency improvement cycle. Each functional unit in the operation efficiency improvement cycle will be described.
[0018]
(1) Planning Function Unit The planning function unit 1 supports quantitatively finding an operation region in which an improvement in operation efficiency is expected by automation in plant operation based on data obtained by plant operation. The plan function unit 1 analyzes the event log collected from the DCS.
[0019]
FIG. 3 is a diagram showing an example of a screen used for analysis.
The planning function unit 1 collects event logs stored in the DCS, and uses an ETB graph (Event Balance Trend Graph) to request an operation request amount (process alarm, annunciator message, operation guidance, etc.) and an operation amount (operation amount MV, setting). By displaying the time series balance of the quantity SV, the operation mode of automatic operation or manual operation), the problematic operating area is highlighted.
[0020]
In the window 10 of FIG. 3, an ETB graph showing the balance between the operation request amount 11 and the operation amount 12 in time series is displayed. As a result, the occurrence time (When) of the problematic driving is narrowed down.
In the window 13, the type (What) of the issued operation request is displayed as a pie chart.
The window 14 displays an operation request generation source (Where).
The window 15 displays a list of operation request occurrence times and messages.
[0021]
Therefore, the analysis screen of FIG. 3 highlights the operation area in question, and the operation request generation time (When), type (What), and generation source (Where) for the operation area in question. It is possible to narrow down problematic tags from information. Since the problem can be seen quantitatively on the analysis screen, it is effective as the original data for improvement.
[0022]
(2) Construction Function Unit Construction function unit 2 constructs an application program for driving automation. The construction function unit 2 prepares each work to be performed in the plant operation as a process part icon, arranges the process part icon on the screen according to the operation procedure, and constructs the work procedure diagram, and the work procedure diagram application program Create It is configured so that a skilled operator can easily and intuitively construct an application program. The configuration will be described.
[0023]
Manual-driven operation
(1) DCS operation (pump start / stop, setting change, ramping, etc.)
(2) DCS monitoring (trend monitoring, balance monitoring, alarms, etc.)
(3) Waiting for conditions (such as when the temperature reaches 100 ° C)
(4) Wait for time (10 minutes wait, 3 o'clock etc.)
(5) Work request (manual valve opening / closing, on-site indicator check, etc.)
Etc.
[0024]
The construction function unit 2 prepares these operations as process part icons. The icon can be newly created by the user. FIG. 4 shows an example of process component icons. The process part icon represents the work content with a picture. A skilled operator can construct a work procedure diagram of an automation sequence (business flow) by arranging these process component icons on the screen according to the operation procedure that he / she normally performs. Since the work procedure diagram is expressed by, for example, a familiar flowchart, it is very effective in sharing driving knowledge.
[0025]
5 and 6 are diagrams showing examples of business flows.
In FIG. 5, the processing performed in a process unit in the business flow is shown as a business flow, and the processing performed in a process unit in the business flow is shown as a business flow. ing.
In the business flow of FIG. 6, an icon picture is displayed in the process of the flowchart.
These business flows are displayed on the screen.
[0026]
The construction function unit 2 creates an application program for the work procedure diagram constructed on the screen.
For the process component icons described above, a ready-made program for icon processing is prepared. Process component icons are associated with off-the-shelf programs. When the process component icons are arranged on the screen and the icons are connected to construct a work procedure diagram, the order information attached to the icons, icon connection information, and the like are generated accordingly. An application program corresponding to the work procedure diagram is configured by the generated information and a ready-made program associated with the icon.
[0027]
(3) Operation Function Unit The operation function unit 3 performs the plant operation by executing the application program created by the construction function unit 2. Since the business flow created by the construction function unit 2 can be used as an operation screen as it is, it is not necessary to construct an operation screen separately.
FIG. 7 is a diagram showing an example of the operation screen.
The start and stop of operation can be easily performed by mouse operation in process part icon units, process unit units, and business flow units. During driving, various messages such as alarms and guidance can be displayed as necessary, and driving can be safely and reliably performed.
[0028]
The operation function unit 3 prepares a test operation mode that collects data from the DCS and executes a business flow but does not perform any data setting in the DCS. As a result, application programs can be checked and new operators can be trained without adversely affecting the plant. What you noticed during driving can be added to the work flow by attaching a memo, which is effective for further enhancing the work flow and preventing forgetting correction after driving.
[0029]
(4) Research Function Department The research function part 4 supports the work of evaluating the application program after driving and highlighting the improvements. It is equipped with a driving index display function that displays the actual time taken for each process, the frequency of application program execution delays, and the frequency of intervention operations such as pauses and restarts in a time chart or graph format.
[0030]
(5) Improvement Function Unit The improvement function unit 5 improves the application program based on the improvement points highlighted in the research function unit 4.
[0031]
The processes of the planning function unit 1, the construction function unit 2, the operation function unit 3, the research function unit 4, and the improvement function unit 5 described above are repeated as a cycle.
[0032]
FIG. 8 is a block diagram showing another embodiment of the present invention.
This embodiment is a diagram showing a specific configuration example of the construction function unit 2 and the driving function unit 3.
In FIG. 8, the icon memory 30 is prepared by associating icons representing each work performed in plant operation with a ready-made program for executing the work of this icon. As icons to be prepared, for example, there are icons shown in FIG.
The icon connection means 31 selects an icon from the icon memory 30, connects the selected icon on the screen of the display means 32, and creates a work procedure diagram showing the work procedure of the plant operation on the screen. The work procedure diagram is, for example, a flowchart. As the created work procedure diagrams, there are flowcharts shown in FIGS. 5 and 6, for example.
[0033]
The information generation unit 33 generates information for executing the work procedure created by the icon connection unit 31. Examples of information to be generated include information on the order of icons, icon connection information, and the like. Information (execution information) generated by the information generation unit 33 is dropped into the storage unit 34.
The operation execution unit 35 executes the plant operation according to the work procedure diagram displayed on the screen based on the information generated by the information generation unit 33 and the program associated with the icon in the work procedure diagram. The plant PLT is operated by the operation execution means 35.
[0034]
The input means 36 is provided for performing an input operation necessary for plant operation, for example, with a mouse, a keyboard, or the like. When an icon in the work procedure diagram displayed on the screen on the screen is designated by the input means 36, the operation execution means 35 executes the work of the designated icon. Thereby, a program can be directly executed by a screen operation.
The display control unit 37 controls the display of the display unit 32.
[0035]
FIG. 9 is a block diagram showing another embodiment of the present invention. In FIG. 9, the same parts as those in the previous figure are given the same reference numerals.
The icon memory 30 is prepared by associating an icon indicating exception processing with a ready-made program that executes processing of this icon. The icon memory 30 is also provided with an icon indicating normal processing and its program.
When the exception processing occurs, the icon connection unit 31 connects the icons prepared in the icon memory 30 on the screen and creates a work procedure diagram of the exception processing on the screen.
[0036]
The information generation unit 33 generates information for executing the exception processing work procedure created by the icon connection unit 31. Information (exception processing execution information) generated by the information generation unit 33 is dropped into the storage unit 40.
The exception process execution means 41 executes the plant operation of the exception process according to the exception process work procedure diagram based on the exception process execution information generated by the information generation unit 33 and the program associated with the icon in the work procedure diagram. To do.
The exception processing determination unit 42 determines whether or not exception processing has occurred.
[0037]
In the embodiment of FIG. 9, when the plant operation is stopped due to a communication error or an operator's operation, the exception process determination means 42 determines that an exception process has occurred. As a result, the plant operation shifts to exception processing.
When shifting to the exception process, the icon connection unit 31 connects the exception process icons prepared in the icon memory 30 on the screen, and creates a work procedure diagram of the exception process on the screen.
The information generation unit 33 generates information for executing the created exception processing work procedure. The exception process execution means 41 executes the plant operation of the exception process according to the exception process work procedure diagram.
[0038]
FIG. 10 is a diagram showing an example of a work procedure diagram for exception processing.
When a pause command is entered with the execution status of normal operation, “pause processing” is executed, and a transition is made to the pause status. When the start command is entered, “restart processing” is executed and the execution status is returned.
When a manual end command is input with the execution status of normal operation, “manual end processing” is executed, and a transition is made to the manual end status.
“Pause processing”, “restart processing”, and “manual termination processing” are prepared as exception processing icons.
[0039]
When exception handling occurs, a work procedure diagram for exception handling is displayed on the screen. Thereby, the operator can recognize on the screen what kind of processing is being performed.
[0040]
FIG. 11 is a block diagram showing another embodiment of the present invention.
This embodiment is a plant operation apparatus that has a test operation mode.
The operation execution means 35 inputs data (for example, process data) from the plant PLT and outputs a signal for executing the plant operation in response to this input. This output is dropped into the verification information storage means 50. The dropped output information is read by the memory control means 51 and displayed on the screen by the display means 32.
[0041]
In the embodiment of FIG. 11, when the trial operation mode is entered, the operation execution means 35 inputs data from the plant PLT and generates an output corresponding to this input. This output is displayed on the screen of the display means 32. The operator looks at the output displayed on the screen and verifies whether or not the operation execution means 35 is operating the plant normally.
In this embodiment, a signal is received from the plant, but verification is performed without giving a signal to the plant. Therefore, verification can be performed without adversely affecting the plant.
[0042]
FIG. 12 is a block diagram showing another embodiment of the present invention.
This embodiment is also a plant operation apparatus that has a test operation mode.
In the verification information storage means 50, there is a virtual plant 52 prepared with the same data as the data coming from the plant. The virtual plant 52 is configured by a data table, for example.
[0043]
In the embodiment of FIG. 12, the memory control means 51 reads data from the virtual plant 52. The read data is given to the operation execution means 35 as an input from a pseudo plant. The operation execution means 35 inputs the read data and outputs a signal for executing the plant operation in response to this input. This output is displayed on the screen of the display means 32. The operator looks at the output displayed on the screen and verifies whether the operation execution means 35 is operating the plant normally.
[0044]
The operator can change the data of the virtual plant 52 via the input means 36 and the memory control means 51. Thereby, the input from the pseudo plant can be changed.
In this embodiment, by preparing a virtual plant, verification is performed (offline) without exchanging signals with the actual plant. Therefore, verification can be performed without adversely affecting the plant.
[0045]
【The invention's effect】
According to the present invention, the following effects can be obtained.
[0046]
In the invention of claim 1, an operation efficiency improvement cycle composed of five functions of planning, construction, operation, research, and improvement is prepared, and these five functions are executed in order. As a result, operating efficiency can be reliably and continuously maintained and improved by reducing operating time loss and reducing raw material and utility losses. In addition, it is possible to prevent the application program from becoming obsolete due to changes or improvements in the process or operation method. Furthermore, while the number of experienced operators is rapidly decreasing, safety can be secured and operation know-how can be inherited.
[0047]
According to the invention of claim 2, the skilled operator can easily create a work procedure diagram by connecting icons on the screen. At the same time, a program for executing the created work procedure diagram is also created. The new operator can easily operate the plant based on the created work procedure diagram. For this reason, the operation quality can be homogenized by passing on the operation know-how of the skilled operator to the new operator.
[0048]
According to the invention of claim 3, since the work procedure diagram is a flowchart, it is possible to clarify on the screen the processing procedure of a complicated branch or loop that occurs in the operation procedure. As a result, it is possible to express a driving procedure according to the current situation.
[0049]
According to the invention of claim 4, the plant operation can be executed by directly operating the work procedure diagram created on the screen.
[0050]
According to the invention of claim 5, when the plant operation shifts to the exception process, the work procedure manual for the exception process is displayed on the screen, so that the operator can easily grasp the progress of the exception process. Further, since the operation procedure manual for exception handling is constructed by connecting icons on the screen, the operator does not need to create an environment for exception handling independently.
[Brief description of the drawings]
FIG. 1 is a configuration diagram showing an embodiment of the present invention.
FIG. 2 is a conceptual diagram of an operation efficiency improvement cycle.
FIG. 3 is a diagram showing an example of a screen used for analysis.
FIG. 4 is a diagram showing an example of process part icons.
FIG. 5 is a diagram illustrating an example of a business flow.
FIG. 6 is a diagram illustrating an example of a business flow.
FIG. 7 is a diagram showing an example of an operation screen.
FIG. 8 is a block diagram showing another embodiment of the present invention.
FIG. 9 is a block diagram showing another embodiment of the present invention.
FIG. 10 is a diagram showing an example of a work procedure diagram for exception handling.
FIG. 11 is a block diagram showing another embodiment of the present invention.
FIG. 12 is a block diagram showing another embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Plan function part 2 Construction function part 3 Operation function part 4 Research function part 5 Improvement function part 30 Icon memory 31 Icon connection means 32 Display means 33 Information generation means 35 Operation execution means 36 Input means 41 Exception processing execution means 50 Verification information Storage means 51 Memory control means

Claims (5)

In a plant operation apparatus that executes plant operation according to a predetermined procedure,
Based on the data obtained by plant operation, a planning function unit that assists in quantitatively finding out the operation area in which operation efficiency is expected to be improved by automation in plant operation,
Prepare each work to be performed in plant operation as a process part icon, select the prepared process part icon and arrange it on the screen according to the operation procedure, and create a work procedure diagram and create an application program for the work procedure diagram A construction function unit to
An operation function unit that executes the application program created by this construction function unit to operate the plant,
A research function to help evaluate application programs after driving and highlight improvements,
An improvement function section that improves the application program based on the improvements highlighted in this research function section,
The plant operation apparatus characterized by repeating the process of the planning function unit, the construction function unit, the operation function unit, the research function unit, and the improvement function unit as a cycle. In a plant operation apparatus that executes plant operation according to a predetermined procedure,
An icon memory prepared by associating icons representing each work performed in plant operation with a ready-made program for executing processing of this icon,
Icon connection means for selecting an icon from the icon memory, connecting the selected icon on the screen, and creating a work procedure diagram showing the work procedure of the plant operation on the screen;
Information generating means for generating information for executing the work procedure created by the icon connecting means;
Based on the information generated by the information generating means and the program associated with the icon in the work procedure diagram, an operation execution unit that executes the plant operation according to the work procedure diagram displayed on the screen,
A plant operation apparatus characterized by comprising: The plant operation apparatus according to claim 2, wherein the work procedure diagram is a flowchart. 3. The plant operating apparatus according to claim 2, further comprising an input unit for designating an icon in the work procedure diagram displayed on the screen, wherein the operation execution unit executes the operation of the icon designated by the input unit. In a plant operation apparatus that executes plant operation according to a predetermined procedure,
An icon memory prepared by associating an icon indicating exception processing with a ready-made program that executes processing of this icon,
Icon connection means for connecting an icon prepared in the icon memory on the screen when an exception process occurs, and creating a work procedure diagram of the exception process on the screen;
Information generating means for generating information for executing the exception handling work procedure created by the icon connecting means;
Based on the information generated by this information generating means and the program associated with the icon in the work procedure diagram, exception processing execution means for executing the plant operation of exception processing according to the work procedure diagram of exception processing,
A plant operation apparatus characterized by comprising:

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