JP2001166818A - Plant operation device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize a plant operation device capable of surely and continuously maintaining and improving the efficiency of operation, preventing an application program from being made commonplace due to the change or improvement of processes or an operation method and uniforming the quality of operation by allowing a new operator to succeed the operation know-how of a skilled operator. SOLUTION: In the plant operation device for executing plant operation in accordance with a prescribed procedure, an operation efficiency improving cycle constituted of five functions, i.e., planning, construction, operation, research, and improvement is prepared and these five functions are successively executed. An operation procedure chart is prepared by connecting respective icons on a screen and a program for executing the prepared operation procedure chart is also simultaneously prepared.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plant operating apparatus which is applied to the operation of a chemical plant, a steel plant and the like, and executes the operation according to a predetermined procedure. More specifically, the present invention relates to a plant operation device devised to support an improvement in operation efficiency.

[0002]

2. Description of the Related Art In plant operation, non-stationary operations typified by start-up, shutdown, grade change, and the like, measures for process abnormalities, equipment abnormalities, control abnormalities, etc., which occur during normal operation, auxiliary operations for control, etc. This is an operation area that is often performed mainly by manual operation. For this reason, unevenness in operation quality (instability of control, loss of operation time, loss of product quality, utility loss, loss of work, etc.) occurs due to differences in skills of operators, and this may be a bottleneck in improving operation efficiency. . Here, the utility loss is a loss of electricity, gas, steam, and the like supplied to the plant.

[0003] In addition, the number of skilled operators is rapidly decreasing due to recent labor savings, and there is an urgent need to pass on operating know-how. However, since the above-described operation region mainly composed of manual operation largely depends on the operation know-how of a skilled operator, there are the following problems in a conventional automation method using a DCS (distributed control system) or a process computer.

[0004] It is inevitable that the completeness of the application program is reduced when the specifications are transmitted from the operator to the instrumentation engineer to the manufacturer. By repeatedly changing and improving processes and operating methods, application programs become obsolete, and a great deal of labor and cost is required to restore the original perfection. A lot of labor is required for operations such as hearings from operators, in-house meetings, meetings with manufacturers, and creation of functional specifications. Therefore, 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 a skilled operator himself to directly, easily and continuously operate the application program from development to maintenance. For this reason, prompt system development has been desired by each user.

[0006] Further, in the conventional plant operation apparatus, there is no apparatus that displays the operation procedure on a screen. For this reason, the driving know-how of a skilled operator was hard to be passed on to a new operator, and the difference in driving quality was large.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned problems, and has a plan, a construction,
An operation efficiency improvement cycle composed of five functions of operation, research, and improvement is prepared, and by executing these five functions in order, the operation efficiency is reliably and continuously maintained.
It is an object of the present invention to realize a plant operation apparatus that can be improved and that can prevent application programs from becoming obsolete due to changes and improvements in processes and operation methods. In 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. It is an object of the present invention to realize a plant operation device that can pass operation know-how to a new operator and homogenize operation quality.

[0008]

SUMMARY OF THE INVENTION The present invention is a plant operating device having the following configuration.

(1) In a plant operation apparatus that executes a plant operation according to a predetermined procedure, based on data obtained by the plant operation, an operation region in which an improvement in operation efficiency is expected in the plant operation by automation is quantitatively determined. A planning function unit that assists in finding items in the factory and each operation to be performed during plant operation are prepared as process part icons, and a work procedure diagram is constructed by selecting the prepared process part icons and arranging them on the screen according to the operation procedure In addition, the construction function unit that creates the application program of the work procedure diagram, the operation function unit that executes the application program created by this construction function unit to perform plant operation, and the application program after operation is evaluated and improved The Research Function Department, which helps to highlight And improving function unit that performs improvement in the application program on the basis of the improvements was to come carving,
A plant operation apparatus comprising: repeating a 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.

(2) In a plant operation apparatus for executing plant operation according to a predetermined procedure, an icon prepared by associating an icon representing each operation performed in the plant operation with a picture and a ready-made program for executing the processing of this icon. Connection means for selecting an icon from the memory for the icon, connecting the selected icon on the screen, and creating a work procedure diagram showing the work procedure of the plant operation on the screen, and the icon connection means Based on the information generation means for generating information for executing the work procedure created in the above, and the information generated by this information generation means and the program associated with the icon in the work procedure diagram,
A plant operation device, comprising: operation execution means for executing plant operation according to a work procedure diagram displayed on a screen.

(3) The plant operation device according to (2), wherein the operation procedure diagram is a flowchart.

(4) There is provided input means for designating an icon in the work procedure diagram displayed on the screen, and the operation executing means executes the work of the icon designated by the input means. Plant operating equipment.

(5) In a plant operating apparatus for executing plant operation according to a predetermined procedure, an icon memory prepared by associating an icon indicating an exception processing with a ready-made program for executing the processing of the icon, When this occurs, the icon prepared in the icon memory is connected on the screen, an exception connection work procedure diagram is created on the screen, and the exception connection work procedure created by the icon connection means is created. Information generating means for generating information to be executed, and a plant for exception handling according to the work procedure diagram for exception handling, based on the information generated by the information generation means and a program associated with an icon in the work procedure diagram. A plant operation device, comprising: exception processing execution means for executing operation.

(6) In a plant operation device for executing plant operation according to a predetermined procedure, operation execution means for inputting data from the plant and outputting a signal for executing plant operation in accordance with the input, Display means for displaying an output of the operation execution means, and preparing a test operation mode for inputting data from the plant to the operation execution means and displaying an output of the operation execution means in accordance with the input on the display means. A plant operation device that supports operation verification of operation execution means.

(7) In a plant operation apparatus for executing plant operation according to a predetermined procedure, verification information storage means in which there is a virtual plant prepared with data from the plant, and memory control means for reading data from the virtual plant. Operation execution means for inputting data read by the memory control means and outputting a signal for executing plant operation in accordance with the input, and display means for displaying an output of the operation execution means. By inputting data from the virtual plant to the operation execution means and preparing a test operation mode in which the output of the operation execution means according to the input is displayed on the display means, it is possible to support the operation verification of the operation execution means. Characteristic plant operation equipment.

(8) The plant operation apparatus according to (7), further comprising input means for writing data in the memory and changing data prepared in the virtual plant.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. FIG. 1 is a configuration diagram showing one embodiment of the present invention. The plant operation device 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. By executing the processing of the five functional units in order,
Form an operation efficiency improvement cycle. FIG. 2 is a conceptual diagram of an operation efficiency improvement cycle. Each functional unit in the operation efficiency improvement cycle will be described.

(1) Planning Function Unit The planning function unit 1 assists in quantitatively finding an operation area in which operation efficiency is expected to be improved by automation in plant operation, based on data obtained by plant operation. I do. The planning function unit 1 analyzes the event log collected from the DCS.

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 generates an ETB graph (Event Balance).
The operation request amount (process alarm, annunciator message, operation guidance, etc.) and operation amount (operation amount MV, set amount S
By displaying the time series balance (V, operation mode of automatic operation or manual operation), the driving region in question is highlighted.

The window 10 shown in FIG.
An ETB graph showing the balance between 1 and the operation amount 12 in time series is displayed. This narrows down the occurrence time (When) of the problematic operation. In window 13,
The type (What) of the issued operation request is displayed in a pie chart. The window 14 displays the source of the operation request (W
Here) is displayed. The window 15 displays a list of operation request occurrence times and messages.

Based on these facts, the operation area in question is highlighted by the analysis screen in FIG. 3, and the time (When) at which an operation request is generated for the operation area in question,
Tags that are problematic can be narrowed down from three types of information, that is, the type (What) and the source (Where). The problem can be seen quantitatively on the analysis screen, which is effective as original data for improvement.

(2) Construction Function Unit The construction function unit 2 constructs an application program for driving automation. The construction function unit 2 prepares each operation to be performed in the plant operation as a process part icon, arranges the process part icons on a screen according to the operation procedure, constructs a work procedure diagram, and executes an application program of the work procedure diagram. Create It is configured so that a skilled operator can easily and intuitively construct an application program. The configuration will be described.

The operation mainly by the manual operation is performed by DCS operation (pump start / stop, setting change, ramping, etc.) DCS monitoring (trend monitoring, balance monitoring, alarm, etc.) Waiting for conditions (eg, when the temperature reaches 100 ° C.) Waiting for time ( Wait for 10 minutes, at 3 o'clock, etc.) Work request (manual valve opening / closing, on-site indicator confirmation, etc.).

The construction function unit 2 prepares these operations as process component icons. The icon can be newly created by the user. FIG. 4 shows an example of the process component icon. The process component icon represents the work content by 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 or she usually performs. Since the work procedure diagram is represented by, for example, a familiar flowchart, it is very effective in sharing driving knowledge.

FIGS. 5 and 6 are diagrams showing examples of the business flow. In FIG. 5, the processing performed in a certain process unit in the business flow is shown as a business flow, and the processing performed in a certain processing unit in the business flow is shown as a business flow. ing. FIG.
In the business flow of (1), an icon picture is displayed in the processing of the flowchart. These business flows are displayed on the screen.

The construction function unit 2 creates an application program of the work procedure diagram constructed on the screen. For the process component icons described above, a ready-made program for processing the icons is prepared. A process component icon is associated with a ready-made program. When process component icons are arranged on the screen and the icons are connected to each other to construct a work procedure diagram, information on the order assigned 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.

(3) Operation Function Unit The operation function unit 3 executes the application program created by the construction function unit 2 to perform plant operation. Since the business flow created by the construction function unit 2 can be directly used as the operation screen, there is no need to separately construct the operation screen.
FIG. 7 is a diagram showing an example of the operation screen. The start and stop of the operation can be easily performed by operating the mouse in units of process component icons, process units, and business flow. During driving, various messages such as alarms and guidance can be displayed as necessary, and driving can be performed safely and reliably.

The operation function unit 3 prepares a test operation mode in which data collection from the DCS and execution of a business flow are performed, but data is not set in the DCS at all. As a result, it is possible to check the application program and train new operators without adversely affecting the plant. What is noticed during driving can be added to the business flow by attaching a memo, which is effective for further enriching the business flow and preventing forgetting to correct after driving.

(4) Research Function Unit The research function unit 4 supports a task of evaluating an application program after driving and highlighting points for improvement. An operation index display function is provided for displaying in a time chart or a graph format the time actually taken in each process, the frequency of execution of an application program being delayed, or the intervention operation such as pause and restart being performed.

(5) Improvement Function Unit The improvement function unit 5 makes improvements to the application program based on the improvement points highlighted by the research function unit 4.

The processing 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 is repeated as a cycle.

FIG. 8 is a block diagram showing another embodiment of the present invention. This embodiment is a diagram illustrating a specific configuration example of the construction function unit 2 and the operation function unit 3. In FIG. 8, the icon memory 30 prepares an icon representing each operation performed in the plant operation with a picture and a ready-made program for executing the operation of the icon in association with each other. The icons to be prepared include, for example, the 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. Examples of the created work procedure diagrams include the flowcharts shown in FIGS. 5 and 6.

The information generating means 33 includes the icon connecting means 3
Information for executing the work procedure created in 1 is generated. The information to be generated includes, for example, information on the order assigned to the icons, connection information of the icons, and the like. The information (execution information) generated by the information generation unit 33 is stored in the storage unit 34. The operation execution unit 35 includes an information generation unit 33
The plant operation is executed according to the work procedure diagram displayed on the screen, based on the information generated in step (1) and the program associated with the icons in the work procedure diagram. The plant PLT is operated by the operation execution means 35.

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 the icon in the work procedure diagram displayed on the screen on the screen is designated by the input means 36, the operation execution means 3
5 executes the operation of the designated icon. Thus, the program can be directly executed by the screen operation. The display control unit 37 controls display on the display unit 32.

FIG. 9 is a block diagram showing another embodiment of the present invention. In FIG. 9, the same components as those described above are denoted by the same reference numerals. In the icon memory 30, an icon indicating an exception process and a ready-made program for executing the process of the icon are prepared in association with each other. The icon memory 3
In 0, an icon indicating a normal process and its program are also prepared. When an exception process 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 process on the screen.

The information generating means 33 includes the icon connecting means 3
Information for executing the exception handling work procedure created in step 1 is generated. The information (exception process execution information) generated by the information generation unit 33 is stored in the storage unit 40. The exception handling execution means 41 executes the plant operation of the exception handling according to the work flowchart of the exception handling, based on the exception handling execution information generated by the information generating means 33 and the program associated with the icon in the work flowchart. I do. The exception processing determining means 42 determines whether or not exception processing has occurred.

In the embodiment shown in FIG. 9, when the plant operation is stopped due to a communication error or an operator's operation, the exception processing determining means 42 determines that an exception processing has occurred. As a result, the plant operation shifts to exception processing. When the process shifts to the exception process, the icon connection unit 31 connects the icon of the exception process prepared in the icon memory 30 on the screen, and creates a work procedure diagram of the exception process on the screen. The information generating means 33 generates information for executing the created exception handling work procedure. The exception handling execution means 41 executes the plant operation of the exception handling according to the work procedure diagram of the exception handling.

FIG. 10 is a diagram showing an example of a work procedure diagram for exception processing. When a pause command is input in the execution status of the normal operation, a “pause process” is executed, and a transition is made to the pause status. When the start command is input, the “restart process” is executed, and the process returns to the execution status. When a manual end command is input in the execution status of the normal operation, the “manual end process” is executed, and the process shifts to the manual end status.
"Pause processing", "Restart processing", "Manual termination processing"
Is provided as an icon for exception handling.

When exception processing occurs, a work procedure diagram of the exception processing is displayed on the screen. This allows the operator to recognize on the screen what processing is being performed.

FIG. 11 is a block diagram showing another embodiment of the present invention. This embodiment is a plant operation device that is provided with a test operation mode. The operation execution means 35 includes a plant PLT
(For example, process data) is input, and a signal for executing plant operation is output in accordance with the 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.

In the embodiment of FIG. 11, when the test operation mode is entered, the operation execution means 35 inputs data from the plant PLT and generates an output corresponding to the 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. In this embodiment, a signal is received from a plant, but verification is performed without giving a signal to the plant. Therefore, verification can be performed without adversely affecting the plant.

FIG. 12 is a block diagram showing another embodiment of the present invention. This embodiment is also a plant operation device that provides a test operation mode. The verification information storage means 50 includes a virtual plant 52 that prepares the same data as the data coming from the plant. The virtual plant 52 is composed of, for example, a data table.

In the embodiment shown in FIG.
Reads data from the virtual plant 52. The read data is provided to the operation execution means 35 as an input from a pseudo plant. The operation executing means 35 inputs the read data, and outputs a signal for executing the plant operation according to the input. This output is displayed on display means 3
2 is displayed on the screen. The operator looks at the output displayed on the screen and verifies whether the operation execution means 35 is operating the plant normally.

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 (off-line) without exchanging signals with a real plant. Therefore, verification can be performed without adversely affecting the plant.

[0045]

According to the present invention, the following effects can be obtained.

According to the first aspect of the present invention, planning, construction, operation,
An operation efficiency improvement cycle consisting of five functions of research and improvement is prepared, and these five functions are implemented in order. As a result, it is possible to reliably and continuously maintain and improve operation efficiency by reducing loss of operation time, loss of raw materials and utilities, and the like. In addition, it is possible to prevent application programs from becoming obsolete due to changes and improvements in processes and operation methods. Further, while the number of veteran operators is rapidly decreasing, safety can be ensured and operation know-how can be inherited.

According to the second aspect of the present invention, a 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 transferring the operation know-how of the skilled operator to the new operator.

According to the third aspect of the present invention, since the work procedure diagram is a flowchart, a complicated branch or loop processing procedure that occurs in the operation procedure can be clarified on the screen. As a result, it is possible to express a driving procedure according to the current situation.

According to the fourth aspect of the present invention, the plant can be operated by directly operating the work procedure diagram created on the screen.

According to the fifth aspect of the present invention, when the plant operation shifts to the exception processing, the work procedure manual for the exception processing is displayed on the screen, so that the operator can easily grasp the progress of the exception processing. Further, since the work procedure manual for the exception processing is constructed by connecting the icons on the screen, the operator does not need to independently create an environment for performing the exception processing.

According to the invention of claim 6, although the signal is received from the plant, the verification is performed without giving the signal to the plant. Therefore, verification can be performed without adversely affecting the plant.

According to the seventh aspect of the present invention, verification is performed by exchanging signals with the virtual plant. Therefore, verification can be performed without an actual plant.

According to the eighth aspect of the present invention, by changing the data prepared for the virtual plant, it is possible to perform various verifications of the pseudo input coming from the plant. Thereby, a variation can be given to the verification.

[Brief description of the drawings]

FIG. 1 is a configuration diagram showing one 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 a process component icon.

FIG. 5 is a diagram showing an example of a business flow.

FIG. 6 is a diagram showing an example of a business flow.

FIG. 7 is a diagram showing an example of an operation screen.

FIG. 8 is a configuration diagram showing another embodiment of the present invention.

FIG. 9 is a configuration diagram showing another embodiment of the present invention.

FIG. 10 is a diagram showing an example of a work procedure diagram of exception processing.

FIG. 11 is a configuration diagram showing another embodiment of the present invention.

FIG. 12 is a configuration diagram showing another embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Planning 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 (8)

[Claims] 1. A plant operation apparatus for executing a plant operation according to a predetermined procedure, based on data obtained by the plant operation, quantitatively determining an operation region in which an improvement in operation efficiency is expected by automation in the plant operation. A planning function unit that assists in finding out and each operation to be performed in plant operation are prepared as process part icons, and a work procedure diagram is constructed by selecting the prepared process part icons and arranging them on the screen according to the operation procedure At the same time, a construction function unit that creates an application program for the work procedure diagram, an operation function unit that executes the application program created by this construction function unit to perform plant operation, and evaluates application programs after operation to improve The research function department that supports embossing and the research function department An improvement function unit for improving the application program based on the sculpted points of improvement, and repeating the processing 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 A plant operation device characterized by the above-mentioned. 2. A plant operation apparatus for executing a plant operation in accordance with a predetermined procedure, comprising: an icon prepared by associating an icon representing each operation performed in the plant operation with a picture and a ready-made program for executing the processing of the icon. An icon connecting means for selecting an icon from the memory for the icon, connecting the selected icon on the screen, and creating a work procedure diagram showing the work procedure of the plant operation on the screen, An information generating means for generating information for executing the created work procedure, and a work procedure diagram displayed on a screen based on the information generated by the information generating means and a program associated with an icon in the work procedure diagram Operation execution means for executing a plant operation according to the following. 3. The plant operation apparatus according to claim 2, wherein the work procedure diagram is a flowchart. 4. The apparatus according to claim 2, further comprising input means for designating an icon in the work procedure diagram displayed on the screen, wherein said operation execution means executes the work of the icon designated by the input means. Plant operation equipment. 5. A plant operation apparatus for executing plant operation according to a predetermined procedure, wherein an icon indicating exceptional processing, an icon memory prepared in association with a ready-made program for executing the processing of the icon, and an exceptional processing occur. Then, the icon prepared in the icon memory is connected on the screen, and an exception handling work procedure diagram is created on the screen. The icon connection means executes the exception handling work procedure created by the icon connection means. Information generating means for generating information for performing the operation, and a plant operation of the exception processing according to the work procedure diagram of the exception processing based on the information generated by the information generation means and the program associated with the icon in the work procedure diagram. A plant operation device comprising: 6. A plant operation apparatus for executing a plant operation according to a predetermined procedure, comprising: operation execution means for inputting data from the plant and outputting a signal for executing the plant operation in accordance with the input; Display means for displaying an output of the execution means, and preparing a test operation mode for inputting data from the plant to the operation execution means and displaying an output of the operation execution means in accordance with the input on the display means. A plant operation apparatus characterized by supporting operation verification of operation execution means. 7. A plant operation apparatus for executing plant operation according to a predetermined procedure, comprising: a verification information storage unit having a virtual plant prepared with data from the plant; a memory control unit for reading data from the virtual plant; Operation execution means for inputting data read by the memory control means and outputting a signal for executing a plant operation in accordance with the input; display means for displaying an output of the operation execution means; By providing data from the virtual plant to the operation execution means and preparing a test operation mode for displaying the output of the operation execution means in response to the input on the display means, the operation verification of the operation execution means is supported. And plant operation equipment. 8. The plant operating apparatus according to claim 7, further comprising input means for writing data in said memory and changing data prepared in a virtual plant.