JP2002202713A - Plant operation training simulator, computer and method for performing simulated calculations on characteristics of plant dynamic using plant model, computer-readable recording medium, and plant model generation method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a plant operation training simulator at a low cost which gives an operator the presence, as though he has operated and monitored actual facilities, and does not give him sense of incongruity. SOLUTION: This plant operation training simulator comprises a computer 4 for performing simulated calculations of plant dynamic characteristics using not the whole plant constituted of a plurality of equipment but using a plant model for operation training on some of a plurality of the facilities, and a control device including a operation console equipment 1 similar to an actual one, and the plant model is a combination of a main model part modeled only on the facilities for training the operator on the operation and a plurality of sub-model parts modeled only on the processes and equipment and/or modeled on the degrees of influences on the process conditions of the facilities for the operation training as disturbance elements, concerning the facilities which are other than those for the operation training but their operation states have influences on the process conditions of the facilities for the operation training.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a large-scale plant in which a plant is composed of a plurality of facilities, and these facilities are monitored and operated by a plurality of control devices. A plant operation training simulator consisting of a computer that performs a simulated calculation of plant dynamic characteristics using a plant model for which some equipment is subjected to operation training, and a control device that includes operation monitoring equipment similar to the actual machine, The present invention relates to a computer, a method, a computer-readable storage medium, and a method for creating a plant model for performing a simulation operation of a plant dynamic characteristic using a plant model.

[0002]

2. Description of the Related Art In recent years, there has been remarkable progress in control devices for monitoring operation of plants, and control devices have been introduced into many plants. FIG. 7 shows the configuration of the control device. CR where operator monitors plant operation
T1a to 1c and controllers 2a to 2d for controlling the plant and collecting data are organically connected via a network 3.

With the introduction of such a control device, the operation of the plant can be centrally monitored by the CRTs 1a to 1c, and high-level automation can be realized by the controllers 2a to 2d. Opportunities for personnel to perform manual operations are decreasing.

[0004] In addition, by improving the reliability of the control device and the equipment, stable operation of the plant has been realized, and the opportunity for the operator to take an action in the event of a trouble has been reduced.

[0005] For this reason, it is difficult to maintain operating skills that can cope with various situations based on only the actual operating experience of the plant, and there is a concern that the skill of the operators may be reduced.

[0006] However, no matter how advanced the control function becomes and the degree of automation advances, the last fort of the operation of the plant is the operator, and the training of the operator who can quickly respond to various situations is an important issue.

[0007] It is known that training by a plant operation training simulator that simulates an actual plant can be highly effective in improving and improving the operating skills of operators. The plant operation training simulator is required to exhibit the same behavior as the plant in response to the operation of the operator so that the operator does not have a sense of incongruity and has a sense of presence as if operating an actual plant. For that purpose, a control device similar to that introduced into the plant and a detailed plant model capable of reproducing the actual plant with high accuracy are required.

FIG. 8 shows a system configuration of a conventional plant operation training simulator. CR with the same device configuration as the actual machine
T1a to 1c and controllers 2a to 2d are organically connected via a network 3, and a computer 4a that performs a simulation operation of a plant dynamic characteristic by a plant model.
4b are connected by the network 5. Computer 4a,
A plurality of units 4b are installed according to the scale of the plant model.

[0009]

However, in order to introduce a plant operation training simulator, it is necessary to purchase equipment having the same number of units and equipment specifications and to construct a detailed plant model. Enormous development costs are required, and the introduction costs are high. As a result, the spread of plant operation training simulators has been delayed.

[0010] The present invention has been made in view of the above points, and is a plant operation training simulator that has the same sense of realism as operating and monitoring actual equipment and does not make the operator feel uncomfortable. The purpose is to provide a low-cost.

[0011]

DISCLOSURE OF THE INVENTION The present invention advantageously solves the problems of the prior art, and the inventors of the present invention have made creative efforts to achieve the above-mentioned object, and as a result, the actual operation of It is possible to provide a plant operation training simulator that has the same sense of realism as monitoring the operation of equipment and does not cause uncomfortable feelings to the operator at low cost. However, the plant operation training simulator of the present invention does not simulate a plant dynamic characteristic by using a plant model in which operation training is performed on some of the plurality of facilities, rather than the entire plant including a plurality of facilities. A computer that performs an operation, and a plant operation training simulator including a control device including an operation monitoring device similar to the actual device, wherein the plant model is
About the main model part that models only the equipment that is the subject of the operation training of the operator, and the equipment whose operation status affects the process state of the equipment that is the object of the operation training in the equipment that is not the object of the operation training , Is a plant model that combines multiple sub-models that model the degree of influence on the process state of the equipment of which the process and equipment alone are modeled and / or trained for operation as a disturbance element. Having.

A computer for simulating plant dynamic characteristics by using the plant model of the present invention is not limited to an entire plant composed of a plurality of facilities, but is a target for operation training of some of the plurality of facilities. A computer that performs a simulation calculation of plant dynamic characteristics by using a plant model as described above, wherein the plant model is a main model unit that models only facilities to be subjected to operation training by an operator, and a facility that is not subjected to operation training. With respect to the equipment whose operation status affects the state of the process of the equipment targeted for the operation training, only the process or the equipment is modeled and / or the degree of the influence on the process state of the equipment targeted for the operation training. Is a plant model obtained by combining a plurality of sub-model parts that are modeled as a disturbance element.

Further, the calculation method of the present invention for simulating a plant dynamic characteristic by using a plant model is not limited to an entire plant composed of a plurality of facilities, but to several facilities of the plurality of facilities for operation training. A calculation method for performing a simulation calculation of a plant dynamic characteristic by using a target plant model, wherein the plant model includes: a main model unit that models only facilities to be subjected to operation training of an operator; For the equipment whose operation status affects the state of the process of the equipment to be subjected to the operation training, the model of only the process or the equipment and / or the conversion to the state of the process of the equipment to be subjected to the operation training is performed. It is characterized in that it is a plant model in which a plurality of sub-models in which the degree of influence is modeled as a disturbance element are combined.

Also, the computer-readable storage medium of the present invention is not limited to a whole plant including a plurality of facilities, but a plant model based on a plant model in which some of the plurality of facilities are subjected to operation training. A computer-readable storage medium storing a program for executing a calculation process for performing a simulation operation of dynamic characteristics, wherein the plant model is a main model unit that models only facilities to be subjected to operation training of an operator. For equipment that is not subject to operation training and whose operation status affects the state of the process of the equipment to be subjected to the operation training, only the process or equipment is modeled and / or the equipment is subjected to the operation training. A plant model that combines multiple sub-model parts that model the degree of That has a feature to the point.

The plant model creation method of the present invention is a plant model used for calculation for performing a simulation operation of plant dynamic characteristics. A plant model creation method for creating a plant model in which some equipment is subjected to operation training, a procedure for creating a main model part that models only equipment to be subjected to operation training of an operator, and an operation training For equipment that is not subject to the above and whose operation status affects the state of the process of the equipment targeted for the operation training, only the process or equipment is modeled and / or the process of the equipment targeted for the operation training is performed. And a procedure of creating a plurality of sub-models in which the degree of influence on the state is modeled as a disturbance element.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings, a plant operation training simulator of the present invention, a computer for performing a simulation operation of a plant dynamic characteristic by a plant model, a method, a computer-readable storage medium, and a method for creating a plant model will be described. An embodiment will be described. First, the outline of a large-scale plant will be described. As shown in FIG. 1, raw materials are initially charged, and finally a product is produced. Raw materials are processed as raw materials through the equipment.

Each facility is composed of a number of devices (motors, pumps, valves, etc.) and processes (thermal reaction processes, chemical reaction processes, etc.). However, each facility is not independent independently of other facilities, and the operation status of the facility affects other facilities.

In such a large-scale plant, when constructing a plant operation training simulator, one operator does not operate all equipment at once, but basically operates in units of equipment. Therefore, the minimum training is possible if only the equipment targeted for training is modeled.

However, as described above, each facility is not independent independently of other facilities, and the operation status of the facility affects other facilities. In order to provide a plant operation training simulator that has the same sense of realism as in the case where operation monitoring is performed and does not cause the operator to feel uncomfortable, it is necessary to consider the operating conditions of other facilities. In this case, if all the related facilities are modeled in detail, the man-hour for developing the model becomes enormous.

FIG. 2 shows the concept of modeling according to the present invention. As for equipment that is targeted for operator training, all processes and equipment that make up the equipment are modeled in detail as a main model unit. On the other hand, facilities that are not subject to operation training and whose operation status affects the state of the process of the facility targeted for operation training are treated as sub-model units.

That is, only a part of the equipment or the process which influences the state of the process of the equipment for the operation training in the component of the equipment is modeled, and in some cases, the modeling of the equipment or the process is performed. The degree of influence on the process state of the equipment for which operation training is performed is treated as a disturbance element without performing the operation. By simplifying the plant model by combining the main model section and multiple sub-model sections, it is possible to realize a plant model with a sense of reality required for operator training with minimum development man-hours. It is possible.

FIG. 3 shows a system configuration of a plant operation training simulator according to the present embodiment. Only the CRT 1 and the controller 2, which are control devices related to the equipment to be trained, and the computer 4, on which a simplified plant model is constructed, are connected via the networks 3, 5.

FIG. 4 shows an example of the configuration of the computer 4.
The computer 4 includes a storage unit 4a in which the above-described plant model is stored, an operation unit 4b for performing a simulation operation of a plant dynamic characteristic using the plant model, and a communication interface 4c for communicating via a network. . Note that the plant model may be stored in an external storage device.

By adopting such a configuration, a minimum required device configuration can be obtained, and a plant operation training simulator can be introduced at a low introduction cost. In the case of training other equipment, the training of the equipment is exchanged by exchanging the operation monitoring software of the CRT 1, the control software of the controller 2, and the plant model of the computer 4 with those of the equipment. It is possible.

(Specific Embodiment) Hereinafter, an example in which the plant operation training simulator according to the present embodiment is applied to a gas cleaning facility of a blast furnace plant in the steel industry will be described with reference to FIGS. I do. As shown in FIG. 5, the blast furnace plant includes a plurality of facilities such as a blast furnace furnace facility, a gas cleaning facility, a raw material charging facility, a hot stove facility, and a cast floor facility. However, each facility is not independent independently of other facilities, and the operation status of the facility affects other facilities.

FIG. 6 shows an example of a model of an operation training simulator for a gas cleaning facility. In gas cleaning equipment,
In particular, it is greatly affected by the condition of the blast furnace body. For example, when blow-through occurs, the flow rate of the blast furnace gas changes as a result, and the influence of the blow-through changes the furnace top pressure, which affects the gas cleaning equipment.

As a preparatory operation for charging the raw materials into the furnace, the pressure inside the hopper needs to be the same as the blast furnace top pressure in the furnace top charging equipment. Gas is often used. In this case, during equalization, the blast furnace gas flow rate decreases,
Affects gas cleaning equipment.

It has been empirically known that the flow rate of the blast furnace gas decreases when the raw material is charged into the furnace.

With respect to the fluctuation of the furnace top pressure accompanying the fluctuation of the blast furnace gas flow rate, the opening degree of the septum valve is changed by the control device to control the furnace top pressure to be within a predetermined range.

However, when the control of the furnace top pressure becomes abnormal and the furnace top pressure becomes higher than the set pressure, the furnace top bleeder is opened and the blast furnace gas containing a large amount of carbon monoxide gas is diffused into the atmosphere. Will be.

In such a case, quick response by manual operation of the operator is indispensable. In addition to drilling and shutting down gas before and after shutting down the blast furnace in gas cleaning equipment, drills for handling abnormalities such as blow-by are indispensable in addition to drills for gas shut-off and gas receiving work.

For this purpose, a model representing the dynamic characteristics of the plant of the gas cleaning equipment is created as a main model part, and detailed models are also created for the components such as the dust catcher DC, the Venturi Scrubber VS and the septum valve.

Further, in consideration of the influence from the blast furnace furnace body, in order to provide a realistic simulator that can be used even when an abnormal state such as blow-through occurs, the blast furnace main equipment and the furnace that most affect gas cleaning equipment are used. Modeling of top-loading equipment is required. Here, as a sub-model part, focusing on the fluctuation of the blast furnace gas flow rate, the blast furnace main equipment creates a model that changes the valve opening degree as a valve to change the blast furnace gas flow rate, and the furnace top charging equipment, A model for varying the blast furnace gas flow rate by applying a stepwise disturbance to the blast furnace gas flow rate is created and connected to the main model section of the gas cleaning equipment.

Therefore, in the training, not only the equipment to be trained but also other equipments affecting the present equipment, a scenario can be created so as to simulate the state of the process and reproduce the actual operation. .

As a result, it is possible to reduce the man-hours required for developing the process model and to model a gas purifying facility having a sense of reality necessary for the training of operators. Further, the control device to be introduced into the plant is provided with 3 to 5 CRTs and 5 to 8 controllers. According to the present embodiment, as shown in FIG. , The controller 2, and the computer 4 for constructing the process model.

Although the embodiment described above is an example in which a gas cleaning facility is used as a training target facility, a similar process model has been developed for a hot stove facility, and a plant operation training simulator for a gas cleaning facility has been developed. By putting the software for controlling and monitoring the hot stove equipment and the process model into the CRT 1, the controller 2, and the computer 4 for constructing the process model, training of the hot stove equipment was enabled.

(Other Embodiments) The above-described computer 4
It is configured by a CPU or MPU of a computer, a RAM, a ROM, and the like, and is realized by operating a program recorded in the RAM or the ROM. Further, means for supplying a program code of software for realizing the functions of the above-described embodiments to a computer, for example, a storage medium storing such a program code is included in the scope of the present invention.

[0038]

As described above, according to the present invention, a plant operation training simulator which has the same sense of realism as in the case where operation monitoring of actual equipment is performed and which does not give an uncomfortable feeling to the operator can be performed at low cost. It has made it possible to obtain the results.

[Brief description of the drawings]

FIG. 1 is a diagram showing a schematic diagram of a large-scale plant.

FIG. 2 is a diagram illustrating a concept of modeling equipment for operation training of an operator.

FIG. 3 is a diagram showing a system configuration of a plant operation training simulator.

FIG. 4 is a diagram illustrating an example of a configuration of a computer 4.

FIG. 5 is a diagram showing an equipment configuration in a blast furnace plant.

FIG. 6 is a diagram showing a plant model of a gas cleaning facility according to an embodiment of the present invention.

FIG. 7 is a diagram showing a configuration of a control device for monitoring operation of a plant.

FIG. 8 is a diagram showing a system configuration of a conventional plant operation training simulator.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 CRT 2 Controller 3, 5 Network 4 Computer which performs simulation operation of plant dynamic characteristics by a plant model 4a Storage unit 4b Operation unit 4c Communication interface

Claims (5)

[Claims] A computer for performing a simulation calculation of a plant dynamic characteristic by using a plant model in which operation training is performed on some of the plurality of facilities, not the entire plant including the plurality of facilities; A plant operation training simulator comprising a control device including the same operation monitoring device as described above, wherein the plant model is a main model unit that models only equipment to be subjected to operation training of an operator, and a target of operation training. Regarding equipment whose operation status affects the state of the process of the equipment to be subjected to the operation training in the external equipment,
It is a plant model that combines a plurality of sub-model parts in which the degree of influence on the process state of the equipment to be modeled and / or trained for operation is only a disturbance element. Plant operation training simulator. 2. A computer for performing a simulation calculation of a plant dynamic characteristic by using a plant model in which some of the plurality of facilities are subjected to operation training, not the entire plant including a plurality of facilities. The plant model, a main model part in which only the equipment to be trained by the operator is modeled; and the state of the process of the equipment whose equipment is not to be trained and whose operation status is the trained target. Equipment that affects
It is a plant model that combines a plurality of sub-model parts in which the degree of influence on the process state of the equipment to be modeled and / or trained for operation is only a disturbance element. A computer that performs a simulated calculation of plant dynamics using a plant model. 3. A calculation method for performing a simulation calculation of a plant dynamic characteristic by using a plant model in which operation training is performed on some of the plurality of facilities, instead of the entire plant including a plurality of facilities. The plant model is a main model unit that models only the equipment to be subjected to the operation training of the operator, and the operation status of the equipment that is not to be subjected to the operation training and whose operation status is the processing of the equipment to be subjected to the operation training. For equipment that affects the condition,
It is a plant model that combines a plurality of sub-model parts in which the degree of influence on the process state of the equipment to be modeled and / or trained for operation is only a disturbance element. A calculation method for performing a simulation calculation of a plant dynamic characteristic by using a plant model. 4. A simulation process for performing a simulation calculation of a plant dynamic characteristic by using a plant model in which operation training is performed on some of the plurality of facilities, instead of the entire plant including a plurality of facilities. A computer-readable storage medium storing a program to be executed, wherein the plant model is a main model unit that models only equipment to be subjected to operation training by an operator; For equipment whose situation affects the state of the process of the equipment subject to the operation training,
It is a plant model that combines a plurality of sub-model parts in which the degree of influence on the process state of equipment for which the process or equipment alone is modeled and / or operation training is modeled as a disturbance element. Computer-readable storage medium. 5. A plant model used for a calculation for performing a simulation operation of a plant dynamic characteristic, wherein not only the entire plant including a plurality of facilities but some of the plurality of facilities are subjected to operation training. A method for creating a plant model in which a main model part is created that models only the equipment that is subject to operator training, and the operating status of equipment that is not subject to operation training. For the equipment that affects the state of the process of the equipment targeted for the operation training, only the process or equipment is modeled and / or the degree of influence on the state of the process of the equipment targeted for the operation training is set as a disturbance element. Creating a plurality of modeled sub-model parts.