JP2003202921A - Plant operation monitoring system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a plant operation monitoring system capable of monitoring devices and facilities of an industrial equipment plant from a remote place, and quickly acquiring equipment information or photographic video information in an office when any failure occurs. <P>SOLUTION: This plant operation monitoring system 10 for monitoring the operation of an industrial equipment plant is provided with a camera 12 for monitoring the operating situation of the device and facility, an alarm 22 for warning the abnormality of the device and facility, measuring equipment for generating a measuring equipment signal from various sensors for monitoring the operation of the equipment and device, and a computer 26 for fetching and storing the video signal, the abnormality signal from the alarm 22, and the measuring equipment signal from the measuring equipment. The video signal and the abnormality signal and the measuring equipment signal can be put on a communication line, and a failure item is judged from the abnormality signal and the measuring equipment signal, and can be communicated to a terminal for managing the equipment and/or a terminal corresponding to each failure item. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to industrial equipment such as pump stations (for sewage, water purification, irrigation and flood control), water and sewage treatment plants, shipbuilding plants, etc., which are provided in remote areas using a communication network. The present invention relates to a plant operation monitoring system for monitoring the operation status of a plant, and more particularly to a plant operation monitoring system for various plants that can exchange information using the Internet.

[0002]

2. Description of the Related Art Conventionally, an operation monitoring system for industrial equipment such as pumping stations, water and sewage treatment plants, shipbuilding plants, etc. has provided a monitoring room at a place where the industrial equipment is installed, and various types of industrial equipment have been installed. In most cases, the status signal output from the sensor is collected and the status of each device is monitored individually (Example 1).

In some cases, when the monitoring place is a remote place, a communication line is used to connect the monitoring facility to the industrial equipment and the operation data is sent to the monitoring facility. In this case, the operation data was sent at regular intervals (Example 2).

On the other hand, in many small-scale plants, the operation of the plant is unmanned only by the control panel. In this case, automatic operation is performed, and the manager regularly monitors the operation by patrol the site (Example 3).

[0005]

Among the above-mentioned examples, the monitoring system of Example 1 is uneconomical because each industrial device requires monitoring equipment and monitoring personnel. There was a problem.

Also, according to the monitoring system of Example 2, the operation data is updated at regular intervals. However, for example, failures may occur suddenly, so the detection of these emergency data may be delayed at the monitoring facility. Therefore, there is a problem that these data cannot always be known quickly.

Further, according to the monitoring system of Example 3, since the manager regularly patrols the site, it is difficult to deal with a sudden accident, and personnel for monitoring are required. There was a problem of becoming economical.

The present invention has been made in view of the above circumstances, and by solving the above problems of the prior art and solving the above problems, an apparatus for an industrial equipment plant at a remote place can be provided.
The objective is to provide a plant operation monitoring system that can monitor equipment and can quickly obtain equipment information and captured video information at the time of failure.

[0009]

In order to achieve the above-mentioned object, the present invention is a plant operation monitoring system in the operation of an industrial equipment plant, and a camera for monitoring the operation status of the device / equipment;・ Alarm devices for warning equipment abnormalities, measuring equipment that generates measuring equipment signals from various sensors that monitor the operation of equipment / equipment, the video signals, abnormal signals from the alarm equipment, and the measuring equipment And a computer that captures and stores the measuring instrument signal of the above, and the video signal, the abnormal signal and the measuring instrument signal are placed on the communication line, and the failure item is judged from the abnormal signal and the measuring instrument signal, and the instrument is managed. Provide a plant operation monitoring system characterized by being able to contact a terminal and / or a terminal corresponding to each failure item That.

According to the present invention, it is possible to monitor the equipment / equipment of an industrial equipment plant at a remote place, and at the time of failure, equipment information and photographed video information can be quickly obtained at an office. In addition, since the equipment manager is directly notified of the details of the failure, it is possible to respond promptly, and to reduce or eliminate the number of fixed staffs and regular patrols. It is possible and economical.

In the above term, "mounted on a communication line"
Means that it is placed on the server and is accessible to those who have access rights. "Alarm device" refers to an alarm device, an alarm panel, and a security device. In addition, outputs from various sensors are converted into analog signals, digital signals and pulse signals to become measuring instrument signals.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to the drawings. FIG. 1 is a schematic diagram showing the configuration of a plant operation monitoring system of the present invention. The plant operation monitoring system 10 is composed of the devices described below.

Cameras 12, 12 ... Are arranged to monitor the conditions such as important equipment and facilities of the plant, places where safety is particularly important, and places where failures are expected from operating conditions. Water quality meter, to monitor the situation in the plant
Analog signal generator 14 such as water level gauge, pressure gauge, flow meter, etc.
Is installed. These signals are converted into measurement signals.

Similarly, a digital signal generating device 16 such as a power device and a power control panel is installed in order to grasp the operating condition in the plant. These signals are converted into measurement signals. In addition, a pulse signal generating device 18 such as an electric energy meter and a flow meter is arranged to grasp the operation status. These signals are converted into measurement signals.

Furthermore, a switcher 20 for switching the images taken by the camera 12, a sequencer 24 for sequentially switching an abnormal signal from an alarm device 22 and the like, and a measurement signal from the measuring devices 14, 16, 18 and the like, and those abnormal signals. A computer 26 is provided for taking in and storing measurement signals and video signals.

When the number of the cameras 12 is one, the switching device 20 for switching the photographed images becomes unnecessary. Also, an abnormal signal from the alarm device 22 or the like and the measuring device 14, 1
A configuration is also possible in which the computer 26 has the function of the sequencer 24 that sequentially switches the measurement signals from 6, 18, etc., and the sequencer 24 is omitted.

As the terminal 30 of the device management office, a computer that can browse the device information on the WWW via a communication line 32 such as the Internet can be used, and the terminal 30 (computer) can browse software and receive mail. Mail software etc. are stored. The terminal 30 is generally of a fixed type.

Also, as the terminals 34, 34 ... Of the respective device managers corresponding to the failure items, the e-mail is received,
Browsable devices, such as mobile terminals, mobile computers, mobile phones, etc. can be used. That is, the terminal 34 is generally of a portable and movable type. In addition,
"WWW" means the World Wide Web.
It is called "Web".

The computer 26 installed in the plant has a function to put the stored device information data and camera-captured image information on the Web. Furthermore, the person in charge of the office or the person who corresponds to the failure item can judge the failure item from the device information data. The ability to contact is provided.

FIG. 2 is an outline of the computer 26 and the like in the embodiment of the present invention. The computer 26 captures and stores the video signal from the switching device 20, the abnormal signal from the alarm device 22, the information from the sequencer 24 that switches the measuring device signals from the measuring devices 14, 16 and 18, and the like. That is, the abnormality signal from the alarm device and the measurement signal from the measuring device are sequentially switched by the sequencer 24,
The data collection unit 2 is periodically loaded into the computer 26.
It is stored in 6A as time, device name, and device status information.

The data that has been taken in is analyzed by the data analysis unit 26.
The file is analyzed in B and filed in the file creation unit 26C (details will be described later). The filed data is sent to the web data registration unit 26D and published on the Internet by a separately provided web server 26E. on the other hand,
When a failure of the device is found by the analysis, the time, the device name, and the details of the failure are mailed to the terminal 30 of the device management office and the terminal 34 of the device administrator.

The data filed by the file creating section 26C is also sent to the mail creating section 26F. In the mail creating unit 26F, a daily operation report is created during normal operation, and the content of the error is documented in the event of an abnormality, and both can be accessed via the communication line 32 as an email.

The terminal 30 of the equipment management office is provided with web browsing software, mail browsing software, a mail receiving section, and the like. The device manager's terminal 34 is provided with mail browsing software, a mail receiving unit, and the like.

FIG. 3 is a schematic diagram showing the construction of a plant in the embodiment of the present invention. Here, an example of the procedure after inspecting and repairing ship equipment at a shipbuilding plant is shown.
Note that the same configuration can be used for drainage of pump stations (for sewage, water purification, irrigation, and flood control) other than shipbuilding plants.

In the figure, water is drawn into the pump well 40 from a river through a natural inflow gate 42. At this time, the screen 44 removes bulky dust and the like, but clogging and damage to the screen 44 may occur due to a large amount of bulky dust and unexpected bulky dust.
Therefore, a monitoring camera 12A is installed in this portion. The water drawn from the river is stored in the pump well 40, and a water level gauge 46 is installed to monitor the water level.

When the ship that has been inspected or repaired departs, the natural inflow gate 42 is closed at a water level at which the ship can depart, and the ship is ejected from the pump well 40. After that, in order to extract the water from the pump well 40 again, the water level of the river water is monitored by the water level gauge 54, and if drainage is possible, that is, if the water level of the river is not higher than the reference water level due to heavy rain, etc., the discharge gate. 52 and the discharge valve 50 are opened, the main pump 48 is started, and water is drained. At this time, the state of each device is monitored by the monitoring camera 12B for safety. The discharge gate 52 and the discharge valve 50 are automatically operated by a motor.

FIG. 4 is a flow chart of a schematic procedure for plant operation monitoring. After the start of the plant operation monitoring system (step S1), first, an abnormality is detected whether or not there is an abnormality in the device / equipment (step S2). If there is no abnormality (No),
It is judged whether or not it is the recording time of the video image of the situation in the plant by the camera (step S3), and if the recording time is not reached (No), the abnormality detection is continued (step S3).
2). If the recording time has been reached (Yes), a plurality of cameras are switched to perform camera photography at each camera installation location (step S4).

Furthermore, device measurement is performed by collecting measurement data from each device (step S5), old registration data, which is an old video image taken by the camera, is deleted, and data to be saved and stored in a computer together with the measurement data is deleted and saved. (Step S6).

Next, it is judged whether or not it is the time when the device monitoring of the current day is completed (step S7). If it is the time when the device monitoring of the current day is completed (Yes), the operation status up to that time is reported daily. Create a daily report in the form of (step S
8). If the device monitoring on the day is not completed (No),
The abnormality detection is continued (step S2).

Finally, it is judged whether or not the device monitoring is to be ended (step S9). If the device monitoring is to be ended (Yes), it is ended (step S10), and if the device monitoring is not to be ended. (No), the abnormality detection is continued (step S2).

On the other hand, at step S2, when an abnormality of the device / equipment is detected (Yes), the system collects data of each measuring device (step S11) and analyzes the content of the accident. The details of the analysis of the accident content will be described later, but the administrator is determined in advance corresponding to the failure item of the device / equipment, and the device administrator's terminal 34, 3
An e-mail in which the accident content is described in 4 ... Is transmitted and created and transmitted (step S12).

After that, the normal periodical recording method is changed (step S13), and the image is taken by the camera 12 at a short time until the end of the abnormality monitoring (step S14) and measured by the measuring devices 14, 16, 18 and the like (step S13). (Step S15)
Is performed. Furthermore, the old registration data, which is the old image captured by the camera, is deleted, and the data to be saved and stored in the computer together with the measurement data is deleted (step S1).
6).

Next, it is judged whether or not it is the end point of the abnormality monitoring (step S17), and if it is the end point of the abnormality monitoring (Yes), it is ended and the normal abnormality detection is continued (step S2). ), If the abnormality monitoring end time has not come (No), the process returns to the loop of camera photographing (step S14).

In order to analyze the collected device information data and detect an abnormality, it is desirable to set the work contents and the device state at that time on the computer 26 in advance. FIG. 5 shows a correspondence relationship between each work for detecting an abnormality in the equipment / equipment and the status of the equipment / equipment. In addition, the processing flow is shown in FIG.
Shown in.

The operation of the plant shown in FIG. 3 is started by operating a work starting device (not shown) set in the control device of the plant operation monitoring system to start the operation (step S51). In the abnormality detection, first, the information of the work activation device is obtained and the content of the current work is confirmed (step S52).

Next, by switching the sequencer, the device operation is confirmed from the measuring device (step S5).
3) Obtain information about the state of the measuring device, and determine whether or not the work content matches the device operation or state (step S54). If the work content and the operation of the device do not match, it is determined that the device is abnormal, and the content is added and described in the error list (step S5).
5).

After that, the same judgment is made for other devices (step S56). After confirming the operation of all the devices (Yes), the contents of the error list are confirmed (step S57). When there is a new additional entry item in the error list (Yes), a mail is created and sent to the person in charge of the device by a method of describing the contents later (step S58). The series of confirmation work is repeated at regular intervals until the current work is completed (step S59). However, regarding the email transmission, the email is sent when abnormal data for a new reason exists in the error list during the work, but the email is not sent for the same reason as the previous confirmation.

When the work is finished, it is judged whether or not a series of works are finished (step S60), and when there is another work, the process waits until the work content is changed. When the work is finished, the monitoring process is finished (step S6).
1).

In the river water drawing work, as shown in FIG. 5, only the natural inflow gate is fully opened, the power reception is cut off, the main pump and the generator are stopped, and the discharge valve and the discharge gate are It is fully closed. During this work,
If the main pump, etc., is activated when the power is turned on, an alarm will be activated to notify the abnormal condition. Even in the inspection of ship equipment, repair work and drainage work, if each equipment is not in the state shown in Fig. 5, it is considered to be abnormal.

Next, a method of recording the image picked up by the camera in normal times and in abnormal times will be described. Since the data volume of device measurement data is not so large, generally, there is no problem in recording capacity even if continuously recorded. However, since the video data captured by the camera has a large data capacity, it is necessary to increase the storage capacity of the storage device for continuous recording. On the other hand, since shooting records in normal times are not so important, it is economical and rational to delete shot images after a certain period of time.

FIG. 7 is a flow chart of a method of recording a video image taken by the camera 12. The conditions for capturing the captured image in the plant by the camera 12 are set in advance (step S101) before the plant equipment operation monitoring device is started (step S102). That is, (1) maximum number of shots, (2) normal shooting frequency, (3) normal shooting image deletion time, (4) abnormal shooting frequency, (5) abnormal shooting image deletion Time is set.

FIG. 8 schematically shows a method of recording a photographed image. The recording location is shown in a pie chart,
It is assumed that the captured video is recorded in the divided areas.
That is, the number of divisions corresponds to the maximum number of records. In the normal photographing interval shown in (1) of the figure, the time scale from the video erasing time to the video erasing time shown in the vicinity of 0:00 to 4:00 and the time scale from the video erasing time to 12:00 Not identical, the latter scale is larger than the former. That is, the scale is changed for convenience of explanation.

In the normal photographing interval shown in (1) of the figure, the photographing erasing time is set in order to save new information near the current time at short time intervals and old information at long time intervals. . For example, it is possible to set such that new information near the current time is recorded at a short time interval (for example, every 5 minutes), and old information one hour or more before is recorded at a long time interval (for example, every 1 hour).

In the abnormal photographing interval shown in (2) of the figure, it is possible to set the time intervals to be constant and record at short intervals (for example, one minute intervals). That is,
The "video erasing time" displayed in the figure is not used, and video information is continuously recorded at short intervals.

In the abnormality detection (step S103) in FIG. 7, in a situation (No) in which no plant abnormality is detected, it is determined whether a predetermined time has elapsed (step S110).
When the predetermined time (Yes) for shooting by the camera is reached, the number of shots is confirmed (step S111). At this time, when the number of shots is not over (No), that is, when the shot video can be saved without being deleted, the video is shot (step S114), but the number of shots is over (Ye).
If s), it is determined whether or not the captured image erasing time has been reached (step S112). If the captured image erase time has not been reached (No), the oldest image within the image erase time is erased (step S115), and if the captured image erase time has been reached (Yes), the oldest captured image is taken. The image is erased (step S113), and the current shooting (step S11)
4) Save the video.

On the other hand, in the abnormality detection (step S10
3) At the abnormal time (Yes), when the predetermined time for photographing by the camera is reached (Y in the predetermined time), it is determined whether the predetermined time has elapsed (Step S104).
es), and then confirm the number of shots (step S10)
5). If the number of shots is not exceeded (No), video is shot (step S107). When the number of shots is over (Yes), the oldest video is erased (step S106) and the video currently shot (step S107) is saved.

Next, it is judged whether or not it is the end point of the abnormality monitoring (step S108), and if it is the end point of the abnormality monitoring (Yes), it is ended (step S109), and the end point of the abnormality monitoring is reached. If not (No), the process returns to the loop of the elapse of a predetermined time of photographing (step S104).

At the time of a failure, an e-mail is sent to the terminal 34, 34 ... Of the device manager based on the result of the failure analysis by the computer. FIG. 9 shows an example of an e-mail address management chart in this case. In this way, by establishing the relationship of device name-administrator-email address in the computer 26 in advance, the E-mail of the administrator of the failed device can be obtained.
I'm making it easy to retrieve the email address.

[0049]

As described above, according to the plant operation monitoring system of the present invention, in order to monitor the safe operation of the plant equipment / equipment, the image information captured by the camera and the monitoring device information from various sensors are displayed. It has a function of saving it on a computer and registering it on the web, and a function of analyzing the collected device information data and automatically determining failure items, and then contacting the manager of the office or equipment / equipment failure item. By doing so, it is possible to reduce or eliminate the number of fixed observers and regular patrols, which is economical.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing a configuration of a plant operation monitoring system of the present invention.

FIG. 2 is a schematic diagram of a computer according to an embodiment of the present invention.

FIG. 3 is a schematic diagram showing a configuration of a plant according to an embodiment of the present invention.

FIG. 4 is a flowchart showing a schematic procedure of plant operation monitoring.

FIG. 5 is a table showing the status of each work and device / equipment.

FIG. 6 is a flowchart showing a procedure for detecting an abnormality in a device / equipment.

FIG. 7 is a flowchart showing a procedure of a method for recording a video image taken by a camera.

FIG. 8 is a graph showing an example of a method of recording a captured image.

FIG. 9 is an example of an e-mail address management diagram.

[Explanation of symbols]

10 ... Plant operation monitoring system, 12 ... Camera, 20
... switcher, 22 ... alarm device, alarm panel and security device, 24 ... sequencer, 26 ... computer, 30 ...
Terminal, 32 ... communication line, 34 ... terminal

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Nobuhiko Sugar             1-14-1 Uchikanda, Chiyoda-ku, Tokyo             Stand Plant Construction Co., Ltd. F-term (reference) 5H223 AA20 CC03 CC08 DD03 DD05                       DD07 EE30                 5K048 AA05 BA23 DA03 DC07 EB02                       EB12 EB13 EB15 FC01 HA01

Claims (3)

[Claims] 1. A plant operation monitoring system for operation of an industrial equipment plant, comprising: a camera for monitoring the operating status of the equipment / equipment; an alarm device for warning the abnormality of the equipment / equipment; and the equipment / equipment. A measuring device that generates a measuring device signal from various sensors that monitor the operation of the, and a computer that captures and stores the video signal, the abnormal signal from the alarm device, and the measuring device signal from the measuring device, Signals, abnormal signals, and measuring device signals will be placed on the communication line, and failure items will be judged from the abnormal signals and measuring device signals, so that the terminal managing the device and / or the terminal corresponding to each failure item can be contacted. A plant operation monitoring system that is characterized by 2. When capturing and saving a video signal, an abnormal signal and a measuring device signal to the computer, the signal is captured and stored at a predetermined time interval during normal operation, and when abnormal, the signal is acquired at a shorter time interval than during normal operation. The plant operation monitoring system according to claim 1, which is stored. 3. When the video signal, the abnormal signal and the measuring instrument signal are taken in and stored in the computer, the signal for a predetermined time immediately before the abnormal state is stored in a package format and placed on a communication line when the abnormal state occurs. Or 2
The plant operation monitoring system described in.