CN110969419A - Replacement method and device for station control PLC system - Google Patents
Replacement method and device for station control PLC system Download PDFInfo
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Abstract
The invention discloses a replacement method of a station control PLC system, which comprises the following steps: constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced; simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process; according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working flow of replacing the station control PLC system to be replaced with the target station control PLC system; and under the condition of receiving a replacement instruction, replacing the station control PLC system to be replaced according to the decomposition result. In the method, the replacement process is simulated in advance to determine the working time sequence card, and the PDCA circulation mode is adopted to decompose the working process according to the working time sequence card, so that the actual parking time can be effectively saved.
Description
Technical Field
The invention relates to the technical field of industrial control, in particular to a replacement method and a replacement device for a station control PLC system.
Background
The upgrading and reconstruction of the station control PLC system of the old pipeline face the current situations that spare parts are lack, the upgrading price of control system software (mostly foreign brand control systems) is high, hardware upgrading software is incompatible, and a key infrastructure control system is not independently controllable, and the industry provides a scheme for replacing the old pipeline control system by an independently controllable product.
However, in the past, the upgrading substitution scheme for the station control PLC system of the old running pipeline is generally implemented by stopping transmission for a full line length (about 15 days), removing the original control system, and then debugging the operation of the newly-built control system, and the implementation period of the scheme is long, so that gas and oil consumption of downstream users of the pipeline is affected, and a plurality of downstream users cannot accept the condition, so that the upgrading substitution work of the station control PLC system of the most continuously-running pipeline is still not carried out.
Disclosure of Invention
In view of the above, the invention provides a replacement method and device for a station control PLC system, which are used to solve the problem that the implementation period of the replacement scheme for upgrading the station control PLC system of an old running pipeline is long in all lines (about 15 days), the original control system is removed, and the operation debugging of the newly-built control system is performed. The specific scheme is as follows:
a replacement method of a station control PLC system comprises the following steps:
constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced;
simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process;
according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working flow of replacing the station control PLC system to be replaced with the target station control PLC system;
and under the condition of receiving a replacement instruction, replacing the station control PLC system to be replaced according to the decomposition result.
Optionally, the method for constructing the target station-controlled PLC system according to the station-controlled PLC system to be replaced includes:
acquiring a control logic of a station control PLC system to be replaced;
according to the control logic, a station control PLC system is constructed;
and carrying out cold state test and simulation test on the station control PLC system to obtain the target station control PLC system.
Optionally, in the above method, when a replacement instruction is received, the station control PLC system to be replaced is replaced according to a decomposition result, and the method further includes:
and when an abnormal condition exists in the replacement process, starting an emergency plan to process the abnormal condition.
Optionally, in the above method, when a replacement instruction is received, the station control PLC system to be replaced is replaced according to a decomposition result, and the method further includes:
and in the replacement process, the switching component of the target station control PLC system is manufactured in a factory prefabrication mode.
The above method, optionally, further includes:
and testing the target station control PLC system under the condition of finishing replacement.
A replacement device for a station-controlled PLC system, comprising:
the system comprises a building module, a control module and a control module, wherein the building module is used for building a target station control PLC system according to the station control PLC system to be replaced, and the target station control PLC system comprises all functions of the station control PLC system to be replaced;
the simulation and establishment module is used for simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system and establishing a working time sequence card according to the simulation process;
the decomposition module is used for decomposing the work flow of replacing the station control PLC system to be replaced with the target station control PLC system by adopting a PDCA (packet data access) cycle mode according to the work timing sequence card;
and the replacement module is used for replacing the station control PLC system to be replaced according to the decomposition result under the condition that a replacement instruction is received.
The above apparatus, optionally, the building module includes:
the acquisition unit is used for acquiring the control logic of the station control PLC system to be replaced;
the construction unit is used for constructing a station control PLC system according to the control logic;
and the test unit is used for carrying out cold state test and simulation test on the station control PLC system to obtain the target station control PLC system.
The above apparatus, optionally, the replacing module further includes:
and the processing unit is used for starting an emergency plan to process the abnormal situation when the abnormal situation exists in the replacement process.
The above apparatus, optionally, the replacing module further includes:
and the prefabricating unit is used for manufacturing the switching component of the target station control PLC system in a factory prefabricating manner in the replacement process.
The above apparatus, optionally, further comprises:
and the test module is used for testing the target station control PLC system under the condition of finishing replacement.
Compared with the prior art, the invention has the following advantages:
the invention discloses a replacement method of a station control PLC system, which comprises the following steps: constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced; simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process; according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working flow of replacing the station control PLC system to be replaced with the target station control PLC system; and under the condition of receiving a replacement instruction, replacing the station control PLC system to be replaced according to the decomposition result. In the method, the replacement process is simulated in advance to determine the working time sequence card, and the PDCA circulation mode is adopted to decompose the working process according to the working time sequence card, so that the actual parking time can be effectively saved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a flowchart of an alternative method for controlling a PLC system according to an embodiment of the present disclosure;
fig. 2 is another flowchart of an alternative method for controlling a PLC system according to an embodiment of the present disclosure;
fig. 3 is a block diagram of an alternative apparatus of a station-controlled PLC system according to an embodiment of the present disclosure.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
The invention discloses a replacement method and a device of a station control PLC system, which are applied to the upgrading and replacement process of the station control PLC system. The total length of the built oil and gas pipelines in 2018 years in China is about 12.4 multiplied by 104km, wherein the total length of the natural gas pipelines is about 8 multiplied by 104km, the total length of the crude oil pipelines is about 2.3 multiplied by 104km, and the total length of the finished oil pipelines is about 2.1 multiplied by 104 km. In which the total length of the pipeline is about 6.4 x 104km for pipeline ages over 10 years, with natural gas pipelines about 3.2 x 104km, crude oil pipelines about 1.9 x 104km and finished oil pipelines about 1.3 x 104km, the pipeline automation system hardware is updated in principle using 8-10 years (typically no more than 10 years) and the software upgraded, according to industry experience. The main problems of the pipeline automation control systems facing the embarrassment of difficult upgrading and reconstruction are: the upgrading modification of the original system faces the problems of spare parts lack, high upgrading price of control system software (mostly foreign brand control systems), incompatible hardware upgrading software, the current situation of non-autonomous controllable products of key infrastructure control systems and the like, and the upgrading replacement implementation method of the traditional operating pipeline control system mostly comprises full-line long-time stop transportation, original system disassembly, newly-built system establishment and operation debugging scheme implementation completion, the scheme influences gas and oil consumption of downstream users, and numerous downstream users cannot accept the condition, so that the upgrading replacement work of the vast majority of continuously-operating old pipeline systems is difficult.
At present, the problems mainly faced by the upgrading of the station control PLC system of the old oil and gas pipeline are as follows:
1. the oil and gas pipeline has important functions and allows the automatic control system to be implemented when the transportation is stopped.
The continuous transmission of oil and gas pipelines ensures the requirements of upstream and downstream users, the transmission stop time is short, the time for reconstruction and replacement operation is limited, a feasible scheme implementation must be completed in a short time, and the time for upgrading and replacing a control system in a station yard is urgent, so that the timeliness is one of the difficulties;
2. the station control PLC system has important functions, and the implementation process ensures that the system is absolutely safe
The station control PLC system is a commander of the oil and gas pipeline, the function of the station control PLC system cannot be replaced, the situations of multiple commands, command confusion, misoperation and the like are not allowed, the oil and gas pipeline is controlled in real time in the normal operation process, and the two problems are solved in the upgrading and replacing operation process.
Therefore, based on the above problem, the present invention provides a replacement method for a station-controlled PLC system, where the execution flow of the replacement method is as shown in fig. 1, and the method includes the steps of:
s101, constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced;
in the embodiment of the invention, before replacement, the PLC system with the replacement station needs to be subjected to field investigation, specific information such as configuration, control function, network architecture and the like of the PLC system with the replacement station is known, and the target station-controlled PLC system is constructed according to the basic information, wherein the target station-controlled PLC system includes all functions of the PLC system to be replaced.
S102, simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process;
in the embodiment of the invention, the live-action simulation rehearsal is executed in the replacement process, in order to make the replacement actual operation process smoother and reduce the interference of unexpected events, the simulation operation needs to be carried out on the replacement process, and the simulation operation is mainly carried out on the manual deployment, the working sequence and the time node of the working state time sequence process of the replacement station field to be upgraded of the finished oil pipeline. An initial working time sequence card is set according to manpower allocation, a working sequence and time nodes in advance according to experience, then adjustment is carried out through live-action preview, problems which possibly occur are found out, a plan is set, and the working time sequence card is obtained after continuous adjustment, wherein the working time sequence card is a working process card taking the time sequence as a reference, a certain determined action which needs to be made at a certain time point and needed manpower resources are defined, and meanwhile needed related matching requirements and problems and emergency plans which possibly occur at the time point are pointed out.
S103, according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working process of replacing the station control PLC system to be replaced with the target station control PLC system;
in the embodiment of the present invention, a preferable process of decomposing a work flow of replacing the target station-controlled PLC system with the to-be-replaced station-controlled PLC system by using the PDCA cycle mode according to the work timing card is as follows:
(1) p plan, establishing a working timing card (already realized by S101-S103);
(2) and D, executing, namely decomposing the work flow of the replacement process according to the work time sequence card, strictly executing according to the work time sequence card in a decomposition principle, and decomposing the work flow of replacing the station control PLC system to be replaced with the target station control PLC system according to the work time sequence card to obtain each work step. For example, step a must be performed after step B, steps C and D must be performed simultaneously, and so on.
(3) And C, checking according to the working time sequence card and the field progress condition, wherein the key step of checking is whether an abnormal condition is found, when the abnormal condition exists, an emergency plan is started for processing, and the abnormal condition can be key progress node delay, equipment shortage or fault in the target station control PLC system and the like. The emergency plan may be a schedule delay or replaced with other alternatives, etc. For example, when an abnormal condition occurs in the execution process of step a, the priority of step a is determined, when the priority of step a reaches a preset level, it is indicated that step a is more critical, an emergency plan may be started, and when step a does not reach the preset level, it is indicated that step a is not critical, and a schedule delay may be executed.
(4) And A, processing the analysis result of the process C, executing an emergency plan of progress delay and abnormal conditions, and ensuring the working progress and quality.
And S104, under the condition that a replacement instruction is received, replacing the station control PLC system to be replaced according to the decomposition result.
In the embodiment of the invention, under the condition of receiving the replacement instruction, the station control PLC system to be replaced is replaced according to the decomposition result, wherein the starting time and the total time in the replacement instruction are specified by an owner, the workflow decomposition is required to be completed before the replacement instruction is issued, and a method of inversing the expected time is generally adopted.
In a further replacement process, in order to shorten the replacement time, factory prefabrication can be adopted to replace field manufacturing for a signal switching component, and a signal switching component comprising a wiring arm and a wire number is prefabricated by adopting engineering implementation tables such as a signal switching component prefabrication table, a terminal wiring table, a wiring terminal corresponding table and the like, wherein the engineering implementation table is generated in the process of carrying out field investigation on the PLC system with the replacement station control and constructing the target station control PLC system.
The invention discloses a replacement method of a station control PLC system, which comprises the following steps: constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced; simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process; according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working flow of replacing the station control PLC system to be replaced with the target station control PLC system; and under the condition of receiving a replacement instruction, replacing the station control PLC system to be replaced according to the decomposition result. In the method, the replacement process is simulated in advance to determine the working time sequence card, and the PDCA circulation mode is adopted to decompose the working process according to the working time sequence card, so that the actual parking time can be effectively saved.
In the embodiment of the invention, when the target station control PLC system is replaced, the target station control PLC system needs to be subjected to trial operation and defect elimination, and the test is mainly performed on each functional module in the target station control system to determine whether each functional module is the same as the function executed by the corresponding functional module in the station control PLC system to be replaced. Ensuring the integrity of the system and the reliability of the function.
In the embodiment of the present invention, an execution flow for constructing a target station-controlled PLC system according to a station-controlled PLC system to be replaced is shown in fig. 2, and includes the steps of:
s201, acquiring a control logic of the station control PLC system to be replaced;
in the embodiment of the invention, when the station control PLC system to be replaced is upgraded, information such as configuration, control function and network architecture of the station control PLC system needs to be known, but the information cannot be directly known in general, so field investigation and reverse analysis of a program need to be carried out, and control logic is deduced from a functional structure.
S202, building a station control PLC system according to the control logic;
in the embodiment of the invention, a station control PLC system with the same function as the station control PLC system to be replaced is established in a laboratory according to the control logic, and the establishment process comprises the following steps: and the control cabinet design optimization, the system architecture construction, the network scheme determination, the control scheme determination and the like are used for realizing all functions of the station control PLC system to be replaced, so that the aim of establishing the station control PLC system to be replaced in a ratio of 1 to 1 in a laboratory is fulfilled.
S203, performing cold test and simulation test on the station control PLC system to obtain the target station control PLC system.
In the embodiment of the invention, after the station control PLC system is built, the station control PLC system is required to be subjected to cold state testing, so that all functions of the station control PLC system to be upgraded are realized, wherein the cold state testing, namely, the system is subjected to power-on and hardware, input and output and control functions are tested after the control system is built, and the main testing aim is to test whether the system can achieve all functions of the station control PLC system to be replaced. After the cold test is finished, the station control PLC system is required to be subjected to simulation test, wherein the simulation test content comprises cabinet wiring, a control scheme, a network scheme and the like, the control function of a replacement station to be upgraded can be required to be realized, when the test is finished and the test requirement is met, the target station control PLC system is obtained, otherwise, if the test requirement is not met, the cold test and the simulation test are carried out again after the station control PLC system is adjusted. Preferably, a test requirement table is established for the test process and the requirement table is subjected to item-by-item test analysis regression.
Further, the establishment step by step according to requirements in the investigation, reversal and building processes comprises the following steps: the method is characterized in that a test document of all relevant test contents, test purposes and test standards such as power-on test, hardware test, software test, functional test, network test and the like is convenient for subsequent calling due to the record of the construction and test process.
In the embodiment of the invention, the target station control PLC system, the cable and other auxiliary materials are prefabricated through a laboratory, the working time sequence card is established according to the simulation process, and the PDCA cyclic check is established, so that the actual parking time of a pipeline can be effectively saved, the availability of the whole upgrading replacement scheme is improved, the newly-built system can be ensured to be operated on line in 3 days, and the problem of timeliness in the whole upgrading replacement process is solved.
Based on the above replacement method for the station-controlled PLC, an embodiment of the present invention provides a replacement device for the station-controlled PLC, where a structural block diagram of the replacement device is shown in fig. 3, and the replacement device includes:
a build module 301, a simulation and build module 302, a decomposition module 303, and a replace module 304.
Wherein the content of the first and second substances,
the building module 301 is configured to build a target station-controlled PLC system according to a station-controlled PLC system to be replaced, where the target station-controlled PLC system includes all functions of the station-controlled PLC system to be replaced;
the simulation and establishment module 302 is configured to simulate a process of replacing the station-controlled PLC system to be replaced with the target station-controlled PLC system, and establish a working timing card according to the simulation process;
the decomposition module 303 is configured to decompose the work flow of replacing the target station-controlled PLC system with the to-be-replaced station-controlled PLC system by using a PDCA cycle mode according to the work timing card;
the replacing module 304 is configured to replace the station control PLC system to be replaced according to the decomposition result when the replacing instruction is received.
The invention discloses a replacement device of a station control PLC system, which comprises: constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced; simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process; according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working flow of replacing the station control PLC system to be replaced with the target station control PLC system; and under the condition of receiving a replacement instruction, replacing the station control PLC system to be replaced according to the decomposition result. In the device, the replacement process is simulated in advance to determine the working time sequence card, and the PDCA circulation mode is adopted to decompose the working process according to the working time sequence card, so that the actual parking time can be effectively saved.
In this embodiment of the present invention, the building module 301 includes:
an acquisition unit 305, a construction unit 306 and a test module 307.
Wherein the content of the first and second substances,
the obtaining unit 305 is configured to obtain a control logic of the station-controlled PLC system to be replaced;
the constructing unit 306 is configured to construct a station-controlled PLC system according to the control logic;
the test unit 307 is configured to perform a cold test and a simulation test on the station control PLC system to obtain the target station control PLC system.
In this embodiment of the present invention, the replacing module 304 further includes: a processing unit 308.
Wherein the content of the first and second substances,
the processing unit 308 is configured to start an emergency plan to process the abnormal situation when the abnormal situation exists in the replacement process.
In this embodiment of the present invention, the replacing module 304 further includes: a prefabrication unit 309.
Wherein the content of the first and second substances,
the prefabricating unit 309 is configured to manufacture the adapter part of the target station-controlled PLC system in a factory prefabricating manner in the replacement process.
In an embodiment of the present invention, the testing apparatus further includes: a test module 310.
Wherein the content of the first and second substances,
the testing module 310 is configured to test the target station-controlled PLC system when the replacement is completed.
It should be noted that, in the present specification, the embodiments are all described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments may be referred to each other. For the device-like embodiment, since it is basically similar to the method embodiment, the description is simple, and for the relevant points, reference may be made to the partial description of the method embodiment.
Finally, it should also be noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.
For convenience of description, the above devices are described as being divided into various units by function, and are described separately. Of course, the functions of the units may be implemented in the same software and/or hardware or in a plurality of software and/or hardware when implementing the invention.
From the above description of the embodiments, it is clear to those skilled in the art that the present invention can be implemented by software plus necessary general hardware platform. Based on such understanding, the technical solutions of the present invention may be embodied in the form of a software product, which may be stored in a storage medium, such as ROM/RAM, magnetic disk, optical disk, etc., and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute the method according to the embodiments or some parts of the embodiments.
The station control PLC system replacement method and device provided by the invention are provided. The detailed description is given, and the principle and the embodiment of the present invention are explained by applying specific examples, and the above description of the embodiments is only used to help understanding the method and the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present invention.
Claims (10)
1. A replacement method of a station control PLC system is characterized by comprising the following steps:
constructing a target station control PLC system according to the station control PLC system to be replaced, wherein the target station control PLC system comprises all functions of the station control PLC system to be replaced;
simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system, and establishing a working time sequence card according to the simulation process;
according to the working sequence card, adopting a PDCA (packet data access) cycle mode to decompose the working flow of replacing the station control PLC system to be replaced with the target station control PLC system;
and under the condition of receiving a replacement instruction, replacing the station control PLC system to be replaced according to the decomposition result, and replacing the station control PLC system to be replaced.
2. The method of claim 1, wherein constructing the target site-controlled PLC system in accordance with the site-controlled PLC system to be replaced comprises:
acquiring a control logic of a station control PLC system to be replaced;
according to the control logic, a station control PLC system is constructed;
and carrying out cold state test and simulation test on the station control PLC system to obtain the target station control PLC system.
3. The method of claim 1, wherein in a case when a replacement instruction is received, replacing the to-be-replaced station-controlled PLC system according to a decomposition result, further comprising:
and when an abnormal condition exists in the replacement process, starting an emergency plan to process the abnormal condition.
4. The method of claim 1, wherein in a case when a replacement instruction is received, replacing the to-be-replaced station-controlled PLC system according to a decomposition result, further comprising:
and in the replacement process, the switching component of the target station control PLC system is manufactured in a factory prefabrication mode.
5. The method of claim 1, further comprising:
and testing the target station control PLC system under the condition of finishing replacement.
6. A replacement device of a station control PLC system is characterized by comprising:
the system comprises a building module, a control module and a control module, wherein the building module is used for building a target station control PLC system according to the station control PLC system to be replaced, and the target station control PLC system comprises all functions of the station control PLC system to be replaced;
the simulation and establishment module is used for simulating the process of replacing the station control PLC system to be replaced with the target station control PLC system and establishing a working time sequence card according to the simulation process;
the decomposition module is used for decomposing the work flow of replacing the station control PLC system to be replaced with the target station control PLC system by adopting a PDCA (packet data access) cycle mode according to the work timing sequence card;
and the replacement module is used for replacing the station control PLC system to be replaced according to the decomposition result under the condition that a replacement instruction is received.
7. The apparatus of claim 6, wherein the building module comprises:
the acquisition unit is used for acquiring the control logic of the station control PLC system to be replaced;
the construction unit is used for constructing a station control PLC system according to the control logic;
and the test unit is used for carrying out cold state test and simulation test on the station control PLC system to obtain the target station control PLC system.
8. The apparatus of claim 6, wherein the replacement module further comprises:
and the processing unit is used for starting an emergency plan to process the abnormal situation when the abnormal situation exists in the replacement process.
9. The apparatus of claim 6, wherein the replacement module further comprises:
and the prefabricating unit is used for manufacturing the switching component of the target station control PLC system in a factory prefabricating manner in the replacement process.
10. The apparatus of claim 6, further comprising:
and the test module is used for testing the target station control PLC system under the condition of finishing replacement.
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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