JP2002358117A - Plant operation controller - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily associate the event of any generated alarm or an operation with time-sequential process data at the time of executing plant operation control. SOLUTION: A plant operation controller is constructed of a personal computer 10 and a programmable logic controller(PLC) 20 as a platform. The personal computer 10 is provided with a trend database 110 for preserving time- sequential trend data for each measuring unit and a history database 116 for preserving history information including an operation history and an alarm history. A data retrieving/extracting part 106 displays the alarm history and the operation history with the time-sequential trend data as necessary. Thus, information related with the generating situation of the alarm or the contents of the operation at that time can be shared by each operator, and data for improving an operation method or a process condition or the like can be acquired.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a plant operation control device, and more particularly to a plant operation control device having a PLC instrumentation system including a personal computer and a programmable logic controller (PLC).

[0002]

2. Description of the Related Art A PLC instrumentation system is constructed on a platform including a personal computer and a PLC, and performs sequence control and process control for the purpose of controlling operation of a plant. Conventional PLC instrumentation systems are generally specialized in plant operation and monitoring functions, and have, for example, the following functions. (A) DDC (Direct Digital Control) and sequence control (b) Alarm generation summary display screen (c) Tuning screen for control instrument (d) Instantaneous data display screen of process state quantity (graphic screen) (e) Process in specific period Time series data display screen of state quantity (f) Instrument panel screen for operation

[0003]

In the conventional PLC instrumentation system for the purpose of operation control, each time an alarm is generated, the problem is dealt with and the system is restored, or the operator monitors the process state and sets the alarm. An operation management method based on seemingly sporadic events (for a certain immediate operator), such as operating when the value approaches, is implemented. In particular, when the same operator does not cope with such a recovery in a shift work or the like, it has been difficult to determine the cause of an alarm generated due to a long-period fluctuation phenomenon.

In order to improve the operation method and process conditions of the plant, it is not enough to understand the frequency of alarms and operations. It is necessary to investigate the short-term process leading to the generation and operation of alarms, It was essential to extract the cause of the occurrence and the operation timing. However, a conventional PLC instrumentation system that provides information suitable for the purpose for which it was performed was not known. Furthermore, even if there is long-term span trend data during plant operation, a separate operation trigger that specifies when to collect the necessary data is required to use it for improving operation methods and process conditions. It is. However, it was generally difficult to determine the conditions for this trigger.

SUMMARY OF THE INVENTION In view of the above, the present invention provides a plant operation that can easily determine the cause of an alarm caused by a failure of a plant or process conditions, and improve the operation method and process conditions during plant operation control. It is an object to provide a control device.

[0006]

In order to investigate the cause of an alarm and to improve the operation method and process conditions, the present inventors have to: (a) Trend of process data over a long span;
Management function (b) Function to manage alarm generation and operation frequency of each instrument. (C) PLC instrumentation system that integrates the function of transmitting the improvement process to the operator with the controller is effective. The present inventors have found that the plant operation management based on the comprehensive operation history including the alarm, the instrument operation, and the trend data can be realized by operating the system according to the present invention.

That is, the plant operation control device of the present invention comprises:
A control unit including a computer and a programmable logic controller for controlling the operation of the plant, and a plant operation control device having a human interface function for displaying the operation state of the plant, a process data storage unit for storing time-series process data of the plant; A history database that stores history information including at least one of a plant operation history and an alarm generation history, time-series process data stored in the process data storage unit, and history information stored in the history database. And a data search / display unit for displaying the data in association with.

The plant operation control device according to the present invention includes a data search / display unit for displaying history information including at least one of an operation history and an alarm generation history in association with time-series process data, thereby providing a time-series The relationship between the trend of the data and the timing of the occurrence of the alarm, and / or the short-term and long-term effects of a specific operation at a certain point on the time-series process data can be easily recognized. Further, by sharing such data among the operators, information that can be used for a unified operation method, improvement of the plant operation method and process conditions, and the like can be obtained.

Here, the data search / display unit includes, for each instrument and corresponding operating point, time-series process data;
It is preferable to display the operation history and the alarm generation history in association with each other. In this case, the mutual relationship can be grasped particularly easily. The ratio of the number of each instrument and the corresponding operating point is
The ratio may be any of 1: 1, n: 1 (n> 1), and 1: n.

The process data storage unit and the history database in the plant operation control device of the present invention are generally used data storage devices and can be used irrespective of their type and specifications as long as they have a desired storage capacity. It is possible.
Further, the data search / display unit may be displayed on the screen at all times, may be displayed on the screen by the operator as needed, or may be output as print data. The time-series data is preferably displayed by compressing the time axis arbitrarily. In this case, the operation history data is also displayed on the compressed time axis.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail based on a plant operation control apparatus according to a preferred embodiment of the present invention with reference to the drawings.

FIG. 1 shows a configuration of a plant operation control device according to an embodiment of the present invention. The plant operation control device basically includes a personal computer 10 and a programmable logic controller (PLC) 20. The PLC 20 includes a sequence processing unit 201 that controls the operation of the plant by sequence control, an alarm processing unit 202 that controls the plant based on the generated alarm, and a DDC processing unit 203 that can individually operate each operating point of the plant. Is done.

The personal computer 10 includes, as functional blocks, a data communication unit 101 for transmitting and receiving data to and from the PLC 20 and a raw data for temporarily storing time-series process data (PLC data) received from the PLC 20 as digital data. A data table 102, a data processing unit 103 for processing data stored in the raw data table 102, a time-series data processing unit 104 for processing time-series process data for each instrument, and a history including operation information and alarm information History data processing unit 10 for processing data
5, a data search / display unit 106 for extracting data as needed from the time-series data processing unit 104 and the history data processing unit 105, associating them with each other, and displaying them on a monitor screen, A knowledge data storage unit 107 for storing data associated with the cause and displaying the data as necessary.

The data processing unit 103 has an engineering unit conversion function, and reads the PLC read from the raw data table 102.
The normalized data on the side is converted into engineering unit data for each instrument. Several normalization methods on the PLC side can be set. For example, if the normalized value is 0 to 10000 and the normalized value at a certain point in time is 3240, the indication value of the flow indicator with an instrument range of 0.0 to 200.0 L / H is 64.8 L / H. H. Time series data processing unit 1
Reference numeral 04 denotes a trend database 110 for storing time-series process data as trend data, an instantaneous value table 111 for temporarily storing time-series data input from the data processing unit 103, and data stored in the instantaneous value table 111. Is extracted as, for example, one minute data, and the data storage unit 112 stores the data in the trend database 110, and reads out the stored trend data as necessary. Trend extraction / compression unit 11 that outputs as 121
And 3.

An operation / monitoring screen display 1 for processing data to be displayed on the operation / monitoring screen
14, an alarm display unit 115 for processing data for alarm display, and operation data from the operation / monitoring screen display unit 114 as operation events, and alarm data including message information from the alarm display unit 115 as alarm events. A history database 1 for extracting each and storing this as history information
16 and the history information stored in the history database 116 is extracted as needed, and compressed to create a compressed file 12.
2 and a message display unit 118 for displaying message information among the history information stored in the history database.

In the above plant operation control device, the PLC 20 operating as a controller includes the DDC processing unit 20.
3 and a sequence processing unit 201 are provided, and control of the plant is performed by one or a combination thereof.
An alarm generated by each instrument is converted into status information of the instrument by the alarm processing unit 202, transmitted to the personal computer 10 via the communication processing unit 101, converted into an alarm flag by the data processing unit 103, and converted to an instantaneous value. Written to table 111. When the alarm flag is 1, the operator is notified of the contents of the flag by the alarm display unit 115 and is recorded in the history database 116 as an alarm event. Here, the alarm flag is set for each instrument,
Lower and lower limit, lower limit, deviation (deviation from the set value over a predetermined value),
Upper limit, upper limit, input cutoff (Input Open), output cutoff (Ou
tput Open).

Regarding the instrument operation, when the setting is changed on the operation / monitoring screen display unit 114 by the operator,
The corresponding tag and the changed value are recorded in the history database 116 as an operation event.

Process data such as temperature, pressure, flow rate, and liquid level in the plant, and set values and manipulated variables of the controller are transmitted from the DDC processing unit 203 of the PLC 20 to the personal computer 10 via the data communication unit 101. The data is converted into engineering units by the data processing unit 103 and written into the instantaneous value table 111. Data storage unit 112
Refers to the instantaneous value of the process data from the instantaneous value table 111 at one-minute intervals and records it in the trend database 110.

The trend extracting / compressing unit 113 executes once a day
The data of 1440 points from 0:00 to 23:59 on the previous day is extracted for each instrument and item, and the extracted information is used as an instrument (tag).
Each compressed file (text file) 121 is created. Here, items are the indicated values, set values,
It is a manipulated variable. Further, the text files in which the number of tags is created are collectively compressed into one file, and the date of the previous day is used as the file name. In the data search / extraction unit 106,
By specifying the tag and the period, the compressed file corresponding to the specified period is decompressed, and the data of the specified tag is extracted.

The history extracting / compressing unit 117 separately extracts, once a day, an alarm event and an operation event that occurred between 0:00 and 23:59 on the previous day, and creates a text file. Then, the created two text files are collectively stored in one compressed file 122, and the file name of the compressed file 122 is set as the date of the previous day. Data search / extraction unit 106
When analyzing data, compressed files 121, 1
22 is decompressed and its contents are temporarily written to a work database (not shown). Data search / extraction unit 106
Displays a list and a graph corresponding to the specified condition by specifying an analysis period, an analysis target (alarm event, operation event), an analysis unit (tag, plant), a unit of a time axis, and the like.

The knowledge data storage unit 107 includes a knowledge database 119 and a knowledge data display unit 120. The operator selects an arbitrary instrument, and the operation control value (alarm set value) of the instrument and the reason for setting it, the phenomenon when the control value is deviated, the content of the influence on the process, and the situation The information about the corresponding measures is extracted from the knowledge database and displayed. This knowledge data is based on the trend data of the long-term span obtained at the time of the previous plant operation control, and the data when the management value for each instrument is reviewed or newly set based on the alarm and operation occurrence frequency, Documents describing the grounds for setting, the phenomena expected in the case of deviating from the set management width, countermeasures in that case, and other operational precautions are stored in a text file and accumulated. In the present system, this knowledge data is referred to as "Know Why".

FIG. 2 shows the fluctuation trend of the data extracted and displayed by the data search / extraction unit.
FIG. 3A shows that the displayed time-series data exceeded the upper limit and the lower limit three times in a total of seven days, and an alarm is generated when the upper limit is exceeded for the first time. FIG. 7B shows that the alarm has been released, and FIG. 7C shows that the alarm is generated when the lower limit is exceeded next time and the alarm is not released by a measure corresponding to the alarm. In this example, the time series data and the history data are displayed in this manner because the alarm is generated three times in one week and the frequency of occurrence is extremely high, and the alarm is not canceled even by the action at the time of the last alarm generation. I have.

From the displayed time-series data, it can be seen from the displayed time series data that the meter indication indicates that the periodic fluctuation has continued from the past, and that the peak value in the periodic fluctuation has gradually increased, It can be understood that the lower limit has been exceeded three times in total, and that the alarm has been released and not released by confirming this when the alarm is generated and performing a specific operation. The display span in the periodic fluctuation is
It can be changed by setting.
One-year time series data is compressed and displayed.

Conventionally, information indicating that an upper limit alarm and a lower limit alarm have been generated and information indicating that the alarm has been released by taking measures as shown in FIGS.
Not necessarily shared by all operators. For this reason,
There have been inconveniences such as a different coping method depending on the operator, and unnecessary or incorrect processing. In this plant operation control system, the information on the occurrence of such an event can be shared by all operators, and the situation in which the alarm was generated, the action taken when the alarm was generated, and the Irrespective of whether or not the alarm has been released, or whether or not the alarm has been generated, information such as the details of the operation performed can be reliably transmitted. Further, by mutually referencing the time-series data and the history information, it is also possible to obtain information such as an operation method for preventing occurrence of an alarm and an improvement in process conditions.

Although the present invention has been described based on the preferred embodiment, the plant operation control device of the present invention
It is not limited only to the configuration of the above embodiment,
Various modifications and changes from the configuration of the above embodiment are also included in the scope of the present invention.

[0026]

As described above, according to the plant operation control apparatus of the present invention, the alarm / operation history information is displayed in association with the time-series data, so that the operation of the plant is controlled and the alarm is generated. And / or frequency of operation,
The generation process can be grasped, and the relationship between the long-term fluctuation of the process and the alarm (operation), which is difficult to grasp by one-time monitoring, can be easily grasped.

[Brief description of the drawings]

FIG. 1 is a functional block diagram showing a configuration of a plant operation control device according to an embodiment of the present invention.

FIG. 2 is a data waveform displayed on a screen by the plant operation control device of FIG.

[Explanation of symbols]

 10: personal computer 101: data communication unit 102: raw data table 103: data processing unit 104: time-series data processing unit 105: history data processing unit 106: data search / extraction unit 107: knowledge data storage unit 110: trend database 111 : Instantaneous value table 112: Data storage unit 113: Trend extraction and compression unit 114: Operation / monitoring screen display unit 115: Alarm display unit 116: History database 117: History extraction and compression unit 118: Message display unit 119: Knowledge database 120: Knowledge Data display units 121 and 122: Compressed file 20: PLC 21: Sequence processing unit 22: Alarm processing unit 23: DDC processing unit

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Minoru Yoneda 1 Tohocho, Yokkaichi-shi, Mie F-term in Mitsubishi Chemical Corporation (reference) 5B069 AA01 AA18 BA01 BA04 BB16 FA05 5H220 BB10 CC09 CX04 CX06 CX08 EE01 EE06 HH01 JJ15 JJ19 KK06 LL04 LL07 MM07 5H223 CC03 DD01 DD03 DD07 EE06 EE08 EE11 EE30 FF06

Claims (2)

[Claims] 1. A plant operation control device having a control unit including a computer and a programmable logic controller for controlling operation of a plant and a human interface function for displaying an operation state of the plant, wherein time series process data of the plant is stored. A process data storage unit, a history database for storing history information including at least one of a plant operation history and an alarm generation history, a time-series process data stored in the process data storage unit, and a history database stored in the history database. A plant operation control device comprising: a data search / display unit that displays history information in association with each other. 2. The data search / display unit displays the time-series process data, the operation history, and the alarm generation history in association with each instrument and each corresponding operating point.
The plant operation control device according to claim 1.