JP2005004367A - Driving operation supporting system in plant or the like - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a driving operation supporting system enabling even an unskilled worker to appropriately and quickly operate by removing a boundary between a board man and a field man. <P>SOLUTION: The system comprises an individual machine monitoring device for monitoring states of individual machines in a field 21; a wide area monitoring device for monitoring the sate of the whole of the field 21; an abnormal monitoring/diagnosis supporting part 6 for supporting detection and diagnosis of an abnormality by analyzing data input from the individual machine monitoring device and the wide area monitoring device; worker terminal devices 3 for providing information about specific operations to workers; and a driving operation supporting part 5 communicably connected to the supporting part 6 and the terminal devices 3, determining the specific operations to be performed by the workers, based on the determination of the supporting device 6 and transmitting the information about the specific operations among preset operation data to the terminal devices 3. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an operation support system for supporting various judgments and operations performed by an operator in a field (field) such as a plant or a factory, and in particular, during unsteady operation such as when materials are switched or an abnormality occurs. The present invention relates to a driving operation support system that enables efficient and appropriate operation with fewer workers.
[0002]
[Prior art]
Conventionally, in the operation of equipment and devices in plants such as oil refining plants and chemical factories, a board man who performs instrument monitoring of these equipment and devices, and the operation of the equipment and devices in the field (site) There are things that are carried out in cooperation with fieldmen who perform inspections, repairs, etc.
[0003]
An example of the work by the cooperation between the board man and the field man will be described by taking a kerosene / light oil desulfurization plant as an example.
First, the configuration of a kerosene / light oil desulfurization plant will be briefly described with reference to FIG.
The desulfurization plant shown in FIG. 11 can desulfurize kerosene or light oil by switching the raw material tank. That is, in this desulfurization plant, a light oil raw material tank 110 and a kerosene raw material tank 120 are provided, a light oil piping system for guiding the light oil raw material from the light oil raw material tank 110 to the desulfurization device 130, and a desulfurization device for the kerosene raw material from the kerosene raw material tank 120. A kerosene piping system leading to 130 is provided.
[0004]
In the light oil piping system, a main valve 111, a pump 112, and a pump discharge valve 114 are provided in order from the light oil raw material tank 110 side. In the kerosene piping system, a main valve 121, a pump 122, A pump discharge valve 124 is provided. As will be described later, the kerosene piping system is branched into a spare piping system downstream of the main valve 121. The spare piping system is provided with a spare pump 123 and a spare pump discharge valve 125.
The light oil product desulfurized by the desulfurization device 130 is stored in the light oil product tank 118, and the kerosene product is stored in the tank 128. The product piping is provided with valves 117 and 127. When the desulfurization of the light oil raw material is performed, the valve 127 is closed. When the desulfurization of the kerosene raw material is performed, the valve 117 is closed, and the light oil product and the kerosene product are mixed. It is supposed not to.
[0005]
FIG. 12 is a diagram for explaining a cooperative operation between a board man and a field man in the above desulfurization plant.
In the desulfurization plant of FIG. 11, main valves 111, 121, pumps 112, 122, 123, pump discharge valves 114, 124, 125, switching valves 117, 127, desulfurization device 130, flow meter, pressure gauge, thermometer, etc. Sensor is attached. Detection results such as the raw material flow rate, discharge pressure, and furnace temperature detected by these sensors are transmitted as monitoring information to the management device 20a of the instrument room 20 where the board man B is located via a communication line. Normally, the management device 20a adjusts the temperature in the furnace of the desulfurization device 130, the driving of the pumps 112, 122, 123, etc., in conjunction with the sensors such as the flow meter, pressure gauge, and thermometer. And a control panel for controlling.
[0006]
As shown in FIG. 12, normally two to three fieldmen F are assigned to one boardman B in the instrument room 20. An instruction to switch the raw material between kerosene and light oil based on the production plan and an instruction to respond when an abnormality occurs are mainly given from the board man B in the instrument room 20 to the field man F in the field 21.
The fieldman F is usually in the field 21 and performs patrol, recording, various field work, data processing, etc., but when an instruction is issued from the boardman B, the fieldman F acts according to the instruction of the boardman B. . The fieldman F carries the wireless pager 24, and instructions from the boardman B are given by voice through the wireless pager 24.
[0007]
An example of the cooperation of operations by the board man B and the field man F using the wireless pager 24 will be described with reference to the flowcharts of FIGS.
FIG. 13 is a flowchart for explaining the cooperation between the board man and the field man when the raw material is switched from light oil to kerosene in the desulfurization plant of FIG. 11, and FIG. 14 shows an abnormality in the pump in the desulfurization plant of FIG. It is a flowchart explaining the cooperation of the board man and the field man in the case.
[0008]
First, the case where the raw material is switched from the light oil raw material to the kerosene raw material based on the production plan and the like will be described.
When the timing of material switching comes, board man B instructs field man F to switch materials (step S101).
The fieldman F moves to the designated desulfurization plant according to this instruction, and starts preparation for switching (step S102).
[0009]
When the arrival at the desulfurization plant where the switching instruction is given and the predetermined preparation is completed, the fieldman F reports the preparation completion to the boardman B using the radio paging 24. Boardman B first instructs confirmation of the field equipment necessary for switching (step S103). In this case, the position of the main valve 121, the pump 122 and the pump discharge valve 124 of the kerosene raw material tank 120 and confirmation of the presence or absence of an abnormality are instructed. The fieldman F confirms these (step S104), and if there is no abnormality, reports to that effect to the boardman B.
[0010]
Receiving this report, boardman B instructs fieldman F to start the switching operation (step S105). At this time, the board man B instructs the field man F in advance on the procedure necessary for the switching operation.
First, the board man B instructs the fieldman F to open the main valve 121 of the kerosene raw material tank 120 and, at the same time, reports the completion of the opening and the presence / absence of abnormality after opening. In accordance with this instruction, the fieldman F opens the main valve 121, confirms that there is no abnormality such as leakage, and reports these to the boardman B (step S106).
When the main valve 121 is an electric valve, the board man B performs the opening operation of the main valve 121. That is, the board man B performs an operation of transmitting a command signal for opening the main valve 121 and at the same time notifies the field man F to that effect. The fieldman F confirms that there is no abnormality such as leakage after the main valve 121 is opened, and reports these to the boardman B.
[0011]
Receiving this report, the board man B operates the management device 20a to drive the pump 122 of the kerosene raw material piping system (step S107).
Next, the board man B instructs the field man F to open the pump discharge valve 124 of the kerosene raw material piping system (step S108), and the field man F opens the pump discharge valve 124 according to this instruction (step S108). Step S109).
The fieldman F confirms that the pump discharge valve 124 has been opened and that there is no abnormality, and closes the pump discharge valve 114 of the light oil raw material piping system (step S110).
[0012]
The fieldman F reports to the boardman B that the pump discharge valve 114 has been closed and that there is no abnormality, and the boardman B that has received this report stops driving the pump 112 of the light oil feed pipe system (step). S111). Then, the fieldman F is instructed to close the main valve 111 of the light oil raw material tank 110 (step S112). The fieldman F closes the main valve 111 according to this instruction (step S113), confirms that the main valve 111 has been closed and that there is no abnormality, and reports that fact to the boardman B. This completes the switching of the raw material from light oil to kerosene (step S114).
When the main valve 121 is an electric valve, the board man B performs an operation of transmitting a command signal for closing the main valve 121 and simultaneously notifies the field man F to that effect.
Fieldman F confirms that main valve 121 is closed and that there is no abnormality, and reports to that effect to boardman B.
[0013]
Next, the cooperation between the boardman B and the fieldman F when an abnormality occurs will be described with reference to FIG. In the following description, it is assumed that an abnormality has occurred in the pump 122 of the kerosene raw material piping system and this pump is switched to the pump 123 of the auxiliary piping system.
The board man B can know from the instruction of the instruments in the instrument chamber 20 that the discharge amount of the pump 122 has rapidly decreased beyond the specified value (step S121).
[0014]
Boardman B, who has found an abnormality in the discharge amount of the pump 122, instructs the fieldman F in charge of the field 21 to confirm the pump 122 (step S123). The fieldman F confirms the pump 122 according to the instruction from the boardman B (step S24). This confirmation can be performed on the basis of an instrument instruction of a flow meter attached to the pump 122, vibration, sound, or the like. When such an abnormality is confirmed, the fact is reported to the board man B using the wireless paging 24.
[0015]
Receiving this abnormality report, boardman B instructs fieldman F to switch pump 122 to spare piping system pump 123, and also instructs confirmation of field equipment necessary for switching (step S125).
In this case, confirmation of the pump 123 of the auxiliary piping system and the pump discharge valve 125 is instructed.
Based on this instruction, the fieldman F checks the field equipment (step S126) and reports to the boardman B that there is no abnormality such as an appearance abnormality or leakage.
Receiving this report, the board man B operates the management device 20a to drive the pump 123 of the spare piping system (step S127).
[0016]
The fieldman F reports to the boardman B that the pump 123 has started driving and has confirmed that there is no abnormality (step S128), and opens the pump discharge valve 125 of the pump 123 (step S129). The fieldman F reports to the boardman B that the pump discharge valve 125 has been opened and that there is no abnormality. Receiving this report, Boardman B instructs to close the pump discharge valve 123 of the pump 121 having an abnormality (Step S130), and the fieldman F closes the pump discharge valve 123 (Step S131). Thereafter, the board man B operates the management device 20a to stop the driving of the pump 121 (step S132).
Thus, the switching from the pump 121 to the pump 123 is completed (step S133).
[0017]
By the way, the above-described conventional work has a problem that the boardman B and the fieldman F require high expertise.
That is, the boardman B must determine whether or not the on-site equipment is operating normally based on various measurement instructions. Must be sent to Man F.
On the other hand, the fieldman F can judge whether the operation state of field devices such as pumps, motors, valves, etc. is normal from vibrations, sounds, etc., and must perform appropriate operations in cooperation with the boardman. I must.
[0018]
However, there is a problem that it takes time and money to train skilled boardmen B and fieldmen F. In addition, there is a problem that work involving a large number of human hands is inefficient and the response to a case where an abnormality occurs depending on the skill level of the boardman or fieldman varies.
Various techniques have been developed for reducing the burden on the boardman B and for assisting the operations of field workers (see, for example, Patent Documents 1 and 2).
[0019]
[Patent Document 1]
JP 2003-51894 A
[Patent Document 2]
JP 2003-134261 A
[0020]
However, although the systems described in these documents are effective in reducing the burden on boardmen and fieldmen and supporting more appropriate judgments and operations, they provide a barrier for the division of roles between boardman and fieldman. It is unsatisfactory in that it is possible to perform operations quickly and appropriately, even if an operator with little experience is not a skilled worker.
[0021]
[Problems to be solved by the invention]
The present invention has been made in view of the above problems, and by removing the boundary between the boardman and the fieldman, it is necessary to reduce the number of personnel involved in the operation of field equipment and to perform some operation. Operation in a plant, factory, etc. (in this specification, these may be collectively referred to as a plant, etc.) where the operation can be performed appropriately and quickly even by a skilled worker. An operation support system is provided.
[0022]
[Means for Solving the Problems]
In order to achieve the above object, an operation support system for a plant or the like according to claim 1 is an operation support system for supporting various operations performed by an operator in a field such as a plant or a factory. , An individual device monitoring device that monitors the status of individual devices in the field, a wide area monitoring device that monitors the state of part or all of the field, and data input from the individual device monitoring device and the wide area monitoring device. An abnormality monitoring / diagnosis support unit that analyzes and supports detection and diagnosis of an abnormality, an operator terminal device that provides information on a specific operation to an operator in the field, and the abnormality monitoring / diagnosis support unit And the operator terminal device is connected to be communicable, and the specific operation to be performed by the worker is determined based on the determination of the abnormality monitoring / diagnosis support unit. From among the preset operation data as a configuration having the driving operation support unit to send the information about the specific operation to the operator terminal.
[0023]
According to the above configuration, the field device monitoring in the field is performed by the individual device monitoring device and the wide area monitoring device. The abnormality monitoring / diagnosis support unit analyzes the data transmitted from the individual device monitoring device and / or the wide area monitoring device, and whether or not an abnormality has occurred. Determine what the contents of. This determination result is transmitted to the worker terminal device and also to the driving operation support unit, and information regarding necessary operations is transmitted from the driving operation support unit to the worker terminal device. Thereby, the operator can know the occurrence of the abnormality and the necessary operation for it. Therefore, the roles of both the board man and the field man can be concentrated on one worker, and even a worker with a low level of skill can perform operations quickly and appropriately.
[0024]
According to the present invention, unmanned operation in a plant or the like can be achieved by automatically operating the field equipment.
That is, as described in claim 2, an operation support system for supporting various operations performed by an operator in a field such as a plant or factory, and an individual device that monitors the status of individual devices in the field An abnormality that supports detection and diagnosis of an abnormality by analyzing a monitoring device, a wide-area monitoring device that monitors the state of a part or all of the field, and data input from the individual device monitoring device and the wide-area monitoring device A monitoring / diagnosis support unit; a drive control device that controls driving of the field device in the field; and the abnormality monitoring / diagnosis support unit and the drive control device that are communicably connected to each other. And a driving operation support unit that transmits predetermined operation information from preset operation data to the drive control device based on the determination.
According to this configuration, since the drive control device performs an operation that has been manually performed by an operator, the operator is not required, and the plant or factory can be unmanned.
[0025]
According to a third aspect of the present invention, it is preferable that an identification unit is provided in each field device, and the field device is specified by reading the identification information of the identification unit. In this case, as described in claim 4, the worker terminal device is provided with a reading unit that reads the identification information of the identification unit, and the field device included in the information transmitted from the driving operation support unit It is good also as a structure which provided the judgment part which judges whether the field device specified by the said identification information corresponds.
By doing in this way, even an inexperienced worker can easily find a field device necessary for a specific operation, and can perform work quickly and reliably.
[0026]
In addition, as described in claim 5, the wide area monitoring device transmits data collected from a plurality of sensors provided at predetermined positions in the field to the abnormality monitoring / diagnosis support unit, and the abnormality monitoring The diagnosis support unit is configured to determine abnormality detection, abnormality occurrence position, and abnormality content based on the data.
For example, occurrence of leakage of high-pressure gas and occurrence of vibration of a pump or the like can be determined by a change in sound of the entire field. In addition, the occurrence position of the abnormal sound can be determined by sound. Therefore, by providing a plurality of microphones in the field and analyzing the acoustic data collected from the microphones, it is possible to automatically determine the occurrence of abnormality, the position where the abnormality has occurred, and the content.
[0027]
Further, in a field that requires the intuition and experience of a skilled person such as the temperature distribution in the furnace, the judgment and operation of the skilled person are made into a database, and the data collected from the wide area monitoring device and the individual equipment monitoring device is stored in the database. It is possible to send the operation of the occurrence of an abnormality and the operation when the abnormality occurs to the worker terminal or the like.
[0028]
In addition, as described in claim 6, data with high randomness such as acoustic data and vibration data may be able to be converted into data having a certain regularity by chaos attractor theory. In such a case, it is possible to determine whether or not an abnormality has occurred based on the converted data.
Further, data that can be patterned by an infrared imaging device, such as heat distribution, can be analyzed using a pattern recognition technique based on neural network processing, as described in claim 7. That is, the normal state pattern prepared in advance is compared with the pattern obtained from the data transmitted from the field. For example, whether or not the difference between the two patterns is within a preset allowable range is detected. Can be detected.
Furthermore, when determining the occurrence of an abnormality, as described in claim 8, data input from both the individual device monitoring device and the wide area monitoring device may be used. By doing so, it becomes possible to make a more accurate determination.
[0029]
The present invention is not limited to the case where an abnormality has occurred, but can also be applied to cases where some kind of operation such as material switching is required. Specifically, as described in claim 9, the driving operation support unit includes information related to other operations excluding an operation at the time of occurrence of an abnormality, and the other information is stored in the operator terminal and / or the drive control device. It is good to comprise so that the information regarding this operation may be transmitted.
In addition, as described in claim 10, when operating information is provided to the worker via the worker terminal device, it is necessary for the worker by using characters, symbols, figures, combinations thereof, or voices. Information should be provided.
[0030]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention will be described in detail with reference to the drawings.
In the following description, FIG. 11 is appropriately referred to as necessary.
FIG. 1 is a block diagram illustrating a configuration of a driving operation support system according to an embodiment of the present invention, and FIG. 2 is a diagram illustrating identification means for identifying field equipment in a field.
[0031]
As shown in FIG. 1, the driving operation support system 1 is configured to operate a management device 2 such as a PC, a portable terminal device 3 such as a mobile PC, and the field device when any operation is required. The system supports the unsteady driving automatic support system 5 that supports the system, and the abnormality monitoring / diagnosis support system 6 that monitors the field and on-site equipment and assists in finding and diagnosing the abnormality, and communicates with each other. And a communication line 7 to be connected.
The communication line 7 may be wired, but at least the communication line 7 connecting the mobile terminal device 3 and the management device 2 is preferably wireless. In addition, a general telephone line can be used as the communication line 7, but a local area LAN may be used.
[0032]
An IC chip for identifying each device is attached to each field device in the field 21. Further, the mobile terminal device 3 is provided with a reading unit (not shown), and the mobile terminal device 3 reads the identification information stored in the IC chip by bringing the reading unit close to the IC chip.
FIG. 2 shows an example of reading the identification information of the valves V1, V2, and V3, and the IC chip 8a, 8b, and 8c attached to each of the valves V1, V2, and V3 by the reading unit 3b of the portable terminal device 3. By reading this identification information, the valves V1, V2 and V3 can be identified.
For example, when the valve V1 is the original valve 121 (see FIG. 11) of the kerosene raw material tank 120, the identification information is input in advance to the IC chip 8a, and the reading unit 3b of the mobile terminal device 3 is connected to the IC 3a. By approaching the chip 8a, it is displayed on the display 3a of the portable terminal device 3 that it is the original valve 121 of the kerosene raw material tank 120.
[0033]
In this case, when the field device instructed to the operator via the mobile terminal device 3 is different from the field device from which the worker has read the identification information, the operator is alerted with an alarm or the like, It is preferable to prevent erroneous operation. For example, in the above example, when there is an instruction through the mobile terminal device 3 to open the main valve 121 of the kerosene raw material tank 120, the ICs of valves other than the main valve 121 (for example, the valve V2) When the chip 8b is read by the reading unit 3b, whether or not the identification information of the IC chip 8b is that of the main valve 121 is compared and an alarm is generated. This comparison may be performed by the mobile terminal device 3, but may be performed by the management device 2, or may be performed by the unsteady driving automatic support system 5.
[0034]
FIG. 3 is a diagram illustrating an example of display contents displayed on the mobile terminal device 3.
As shown in FIG. 3, instructions, guidance, and other information are displayed on the display 3 a of the mobile terminal device 3 with characters and drawings. Of course, it is possible to appropriately give instructions and guidance by voice.
For example, in the case of performing material switching, an instruction for material switching is transmitted from the management device 2 or the unsteady operation automatic support system 5 to the mobile terminal 3, but the display 3a of the mobile terminal 3 is displayed on the display 3a of FIG. As shown in Fig. 2, the text is displayed as “Please switch the No. ○ desulfurization plant from light oil to kerosene”. Of course, it is also possible to give this instruction by voice.
[0035]
In this case, if the operator M desires, as shown in FIG. 3B, the position of “No. ○ desulfurization plant” instructed to switch the raw materials can be shown on the map. Further, for example, as shown in FIG. 3C, the switching procedure when switching from the light oil raw material to the kerosene raw material is guided as “Please switch according to the following procedure”, and the procedure is sequentially displayed after this guidance. You may do it.
Further, when the worker M reads the IC chip of the field device with the reading unit 3b of the portable terminal device 3, for example, as shown in FIG. 3 (d), “This valve is the original valve of the kerosene raw material tank. The content including the identification information of the IC chip is displayed.
[0036]
Then, as shown in FIG. 3E, the operator M is prompted to input a confirmation key every time one procedure is completed, and each procedure is exchanged with the worker M. It is possible to execute while confirming.
As described above, in the driving operation support system of the present embodiment, the operation performed by the worker M in an interactive manner with the mobile terminal device 3 can be supported, and the role that has been shared between the boardman and the fieldman conventionally. It is possible to collect the data in the worker M, and even if the worker M is not an expert, it is possible to execute the predetermined operation reliably and appropriately.
[0037]
Next, details of the unsteady driving automatic support system 5 and the abnormality monitoring / diagnosis system 6 that support various operations of the worker M during the unsteady driving, and find and diagnose abnormalities will be described.
Production management of products produced in the field 21 is managed by a production management computer (not shown). When material switching or the like occurs, this information (production management information) is stored in the production management computer as shown in FIG. To the management device 2. Various monitoring information is transmitted from the field 21 to the management device 2. This monitoring information includes monitoring information from a wide-area monitoring sensor group for detecting part or all of the internal state of the field, and individual field devices such as pumps, valves, reactors, and piping provided in the field. And monitoring information from the individual monitoring sensor group for detecting the state of.
[0038]
Then, the abnormality monitoring / diagnosis support system 6 monitors the occurrence, position and contents of the abnormality, which has conventionally been determined by a skilled boardman or fieldman based on the five senses and experience such as hearing, vision, touch, and smell. Judgment can be made automatically based on information.
Furthermore, in the unsteady driving automatic support system 5, procedures necessary for the operation in the unsteady state are set in advance, and some operation is necessary according to the judgment of the production management information and the abnormality monitoring / diagnosis support system 6. Sometimes, the unsteady driving automatic support system 5 presents the procedure of the operation to the worker M via the mobile terminal device 3.
[0039]
[Abnormality monitoring / diagnosis support system]
Next, the abnormality monitoring / diagnosis support system 6 will be described.
FIG. 4 is a block diagram illustrating a configuration according to an embodiment of the abnormality monitoring / diagnosis support system.
The wide-area monitoring sensor group I includes, for example, one or more infrared cameras 621 that monitor the temperature distribution in the field 21, a plurality of omnidirectional microphones 622 that detect sound in the field 21, One or more temperature sensors 623 that measure the temperature at the appropriate location are included.
[0040]
The individual monitoring sensor group II includes, for example, a microphone 631 attached to the valve V for detecting the sound of the valve V, a temperature sensor 632 attached to the pipe T for detecting the temperature of the pipe T, and a pump P. And a vibration sensor 633 attached to the pump P for detecting the vibration of the motor.
The abnormality monitoring / diagnosis support system 6 is connected to the wide-area monitoring sensor group I and the individual monitoring sensor group II via the I / O interfaces 602 and 603, and the detection results from the infrared camera 621 and the sound collection microphone 631 and the like. Is transmitted to the CPU 601 of the abnormality monitoring / diagnosis support system 6.
[0041]
It should be noted that the abnormality monitoring / diagnosis support system 6 or the management device 2 may determine whether or not an abnormality has occurred based on the monitoring information transmitted from the wide-area monitoring sensor group I and the individual monitoring sensor group II. However, in the following description, it is assumed that the abnormality monitoring / diagnosis support system 6 determines.
When monitoring information is input to the abnormality monitoring / diagnosis support system 6 from the wide-area monitoring sensor group I and the individual monitoring sensor group II, the CPU 601 of the abnormality monitoring / diagnosis support system 6 executes a processing program stored in the database in advance. Read and process.
[0042]
Based on the processing result, the CPU 601 of the abnormality monitoring / diagnosis support system 6 determines whether or not an abnormality has occurred, the position where the abnormality has occurred, the field device, the content of the abnormality, and the like. Information regarding this abnormality is transmitted to the mobile terminal device 3 and also to the unsteady automatic driving support system 5.
The abnormality monitoring / diagnosis support system 6 monitors and diagnoses an abnormality in the following procedure, for example.
[0043]
[Gas leak detection]
An explanation will be given by taking, as an example, gas leak detection in which the gas leak is detected in any of the fields 21 and the position of the gas leak is estimated.
Conventionally, gas leakage has been inspected during patrol by Fieldman F (see FIG. 12). Fieldman F specifies the occurrence of gas leakage and the leakage position based on the leakage sound of gas leaking from the pipes and valves.
In this embodiment, a plurality of omnidirectional microphones 622 arranged in the field 21 are used to monitor changes in sound in the field, and new sound generation and sound source identification are performed with the abnormality monitoring / diagnosis support system 6. In cooperation, the management apparatus 2 determines.
[0044]
As shown in FIG. 4, the acoustic data transmitted from the plurality of microphones 622 of the wide-area monitoring sensor group I is input as digital data to the CPU 601 via the I / O interface 602 and the analog / digital converter. The CPU 601 reads and executes a predetermined processing program stored in advance in the database DB 610 to process the acoustic data.
In general, acoustic data collected omnidirectionally in a wide area is highly random, so when analyzing the acoustic data, the highly random acoustic data is converted to data having a certain law. There is a need to. As such a processing program, for example, a processing program for converting highly random data into data having a certain law based on chaos attractor theory may be used. Such processing methods, apparatuses, and programs are disclosed in, for example, documents such as Japanese Patent Application Laid-Open No. 2002-73587 (“chaos analysis device”) and Japanese Patent Application Laid-Open No. 2000-292392 (“gas measurement device and gas measurement method”). It is described in.
[0045]
FIG. 5A shows a synthesized waveform obtained by synthesizing acoustic data from a plurality of microphones 622 provided in the field 21. The vertical axis of the graph in FIG. 5A indicates the sound intensity, and the horizontal axis indicates time. This seemingly random waveform I can also be converted into a waveform II having a certain law as shown in FIG. 5B by processing based on the chaotic attractor theory.
FIG. 6A shows a case where the acoustic data changes due to gas leakage. In FIG. 6A, it is assumed that gas leakage starts at time T0 and acoustic data having a constant waveform (indicated by reference numeral III) is newly added as indicated by a virtual line. Due to the gas leakage, the shape of the synthetic waveform I so far changes as indicated by reference numeral IV.
Therefore, as shown in FIG. 6B, the waveform according to the chaotic attractor theory also changes, for example, as indicated by symbol II ′.
[0046]
Thus, when a change occurs in the acoustic data, the waveform according to the chaos attractor theory also changes, so that it is possible to determine the occurrence of some abnormality by monitoring the waveform according to the chaos attractor theory. Further, by comparing the waveform after the change with the waveform before the change, the frequency of the newly added sound source can be predicted, and the content of the abnormality, in this example, gas leakage can be determined from this frequency.
Next, a procedure for determining the position of gas leakage will be described.
[0047]
[Judgment of gas leakage position]
If it is determined in the above process that a gas leak has occurred, then the location where the gas leak has occurred is determined.
As described with reference to FIG. 6A, when a new sound source is generated, the waveform of the acoustic data from the sound source is added to the waveform of the existing acoustic data, and the sound intensity (amplitude) of the synthesized waveform is increased. Change. The example shown in FIG. 6A shows a case where the amplitude of the combined waveform so far has increased.
[0048]
The abnormality monitoring / diagnosis support system 6 analyzes the acoustic data waveforms of the individual microphones 622 after judging the discovery and content of the abnormality based on the synthesized waveform of the acoustic data.
When analyzing the waveform of the individual acoustic data of the microphone 622, the rate of change in the amplitude of the waveform of the acoustic data before and after the generation of a new sound source (gas leakage position) is larger as it is closer to the new sound source. Therefore, the acoustic data waveforms of the three microphones 622 having a large change rate of the acoustic data waveform are extracted from among the plurality of microphones 622 provided in the field.
FIGS. 7A to 7C show waveforms of acoustic data of three microphones 622 having a large waveform change rate among non-directional microphones 622 in the field. FIG. 7D is a diagram for explaining the procedure in the case of specifying the gas leak position based on the rate of change of the waveform of the acoustic data, and symbol A in each graph of FIGS. 7A to 7C. , B, and C correspond to the regions A, B, and C in FIG.
[0049]
Next, the distance from the extracted three microphones 622 to the sound source is determined. Since it can be determined that the amplitude change rate of the waveform of the acoustic data is inversely proportional to the distance from the new sound source to the microphone 622, the distances R1, R2, and R3 from the three microphones 622 are set according to this ratio. Then, when a circle (region A, B, C) having a radius of distance R1, R2, R3 is drawn around each microphone 622, it can be determined that the sound source is located at the center of the intersection. .
In this way, it is possible to determine the occurrence of an abnormality from the change in the combined waveform and to determine the position where the abnormality has occurred from the waveform change rate of the acoustic data of each microphone. Then, by superimposing this position on the map of the field stored in advance in the database, it becomes possible to identify the field device where abnormality such as gas leakage has occurred.
[0050]
[Temperature distribution abnormality detection]
Next, the case where the temperature abnormality in the furnace of a desulfurization apparatus is detected is demonstrated. Conventionally, a skilled board man monitors the distribution of the temperature in the furnace, and judges the abnormality of the temperature in the furnace from the temperature distribution of a plurality of furnace thermometers and his own experience.
In this embodiment, the abnormality monitoring / diagnosis support system 6 determines an abnormality in the furnace temperature based on the thermal image transmitted from the in-furnace infrared camera of the individual monitoring sensor group II.
[0051]
One or a plurality of in-furnace infrared cameras are provided in the furnace of the desulfurization apparatus 130, and image a specific area in the furnace.
FIG. 8A shows a specific area 140 in the furnace that is a subject of photographing. A temperature distribution pattern 141 in FIG. 8B is obtained by photographing the specific area 140 with an infrared camera and color-coding it into a plurality of temperature patterns based on the photographed image. As shown in the figure, in this example, the temperature distribution is divided into three color patterns of red (indicated by reference numeral 141a), orange (indicated by reference numeral 141b), and purple (indicated by reference numeral 141c).
Then, a normal temperature distribution pattern is collected using, for example, a known neural network technique, and a large number of normal temperature distribution patterns are accumulated, and a database is formed as shown in FIG. 8C (normal temperature distribution patterns accumulated in the database). Are denoted by reference numerals D1, D2, D3.
Here, as the neural network, a self-organizing neural network proposed by Kohonen may be used. This type of neural network is used for, for example, recognition of handwritten input characters, and can collect similar groups and group them, and is characterized by excellent pattern recognition (for example, Ritsumeikan University) Department of Informatics, Faculty of Science and Technology Kamei, Kasari et al. (See 1998 paper "Handwritten characters by fuzzy learning vector quantization method").
[0052]
Therefore, using this self-organizing neural network technology, a normal temperature distribution pattern most similar to the temperature distribution pattern 141 (see FIG. 8B) based on an image taken at a certain time is stored in the database. The normal temperature distribution patterns D1, D2, D3 (see FIG. 8C) are extracted and compared with the extracted normal temperature distribution pattern (for example, temperature distribution pattern D1).
This comparison may be performed, for example, by dividing the captured image into a mesh shape and obtaining a color difference for each of the divided sections. If the color difference between the two is within a preset allowable range, it is determined that the furnace temperature distribution is normal, and if the color difference is outside the allowable range, it is determined that the furnace temperature distribution is abnormal. Moreover, when it is determined that there is an abnormality, it is possible to identify an abnormal location in the furnace by determining which section has an abnormal temperature.
[0053]
[Description of the operation of the driving support system]
Next, an operation procedure using the driving operation support system configured as described above will be described.
First, the case where the raw material is switched from the light oil raw material to the kerosene raw material in the desulfurization plant of FIG. 11 will be described with reference to the flowchart of FIG. 9.
When it becomes necessary to switch the raw materials according to the production plan, the worker inputs the raw material switching to the portable terminal (step S1). Thereby, the raw material switching program of the unsteady operation support system is started (step S3).
The raw material switching program first instructs the operator to confirm on-site equipment necessary for switching the raw material. This instruction is transmitted from the management device 2 to the portable terminal of the worker who has input the material switching via the communication line.
At this time, the raw material switching program designates the main valve 121, the pump 122, and the pump discharge valve 124 of the kerosene raw material tank 120 as field devices to be confirmed when switching from the light oil raw material to the kerosene raw material (step S4).
[0054]
The operator moves the reading unit of the portable terminal closer to the IC chip of the valve or pump, and confirms the positions of the main valve 121, the pump 122, and the pump discharge valve 124 of the kerosene raw material tank 120. At this time, an alarm may be generated when the identification information of another valve or pump IC chip not related to switching to kerosene raw material is read. By doing in this way, even an operator who is not familiar with the field equipment can surely find the field equipment (in this case, the main valve 121, the pump 122, and the pump discharge valve 124) necessary for switching the kerosene raw material. .
[0055]
The operator confirms the positions of the main valve 121, the pump 122, and the pump discharge valve 124 of the kerosene raw material tank 120, confirms that there is no leakage or abnormal appearance, and operates the confirmation key. The end of confirmation of these field devices is input to the unsteady operation support system (step S5).
The unsteady operation support system that has received this confirmation information next sequentially instructs the procedures necessary for switching the raw material from light oil to kerosene.
First, the unsteady operation support system instructs to open the main valve 121 of the kerosene raw material tank 120 (step S6).
[0056]
The operator opens the main valve 121 according to this instruction (step S7), confirms that there is no abnormality such as leakage, operates the confirmation key, and transmits it to the unsteady operation support system (step S8). .
The unsteady operation support system that has received this confirmation information drives the pump 122 for the kerosene raw material tank 120 via the management device 2 (step S9).
Next, the unsteady operation support system instructs the operator to open the pump discharge valve 124 of the pump 122 (step S10). The operator who has received this instruction opens the pump discharge valve 124 (step S11), confirms that there is no abnormality such as leakage, operates the confirmation key, and transmits it to the unsteady driving support system (step S12). .
[0057]
The unsteady operation support system that has received this confirmation information instructs the operator to close the pump discharge valve 114 of the pump 112 of the light oil raw material tank 110 (step S13).
The operator closes the pump discharge valve 114 according to this instruction (step S14), confirms that there is no abnormality, and inputs it to the unsteady operation support system (step S15).
The unsteady operation support system that has received this confirmation information stops the operation of the pump 112 of the light oil raw material tank 110 via the management device 2 (step S16), and closes the main valve 111 of the light oil raw material tank 110. (Step S17). The fieldman F closes the main valve 111 according to this instruction (step S18), confirms that there is no abnormality, and transmits confirmation information to the unsteady operation support system (step S19). This completes the switching of the raw material from light oil to kerosene (step S20).
[0058]
Next, an operation procedure when any abnormality occurs will be described with reference to the flowchart of FIG.
As described above, the abnormality monitoring / diagnosis support system 6 performs the discovery of the abnormality and the specification of the abnormality occurrence position.
In the following description, for convenience of explanation, a case where an abnormality occurs in the pump 122 of the kerosene piping system and the pump 122 is switched to the pump 123 will be described as an example.
[0059]
Abnormality of the pump 122 can be detected by sound, vibration, discharge pressure, discharge flow rate, or the like. Further, the detection can be performed by any of various sensors included in the wide-area monitoring sensor group I or various sensors included in the individual monitoring sensor group II.
The abnormality monitoring / diagnosis support system 6 detects this abnormality when an abnormality occurs (step S30), and identifies the content of the abnormality and the position where the abnormality has occurred (step S31).
Next, the occurrence, content, and position information of the abnormality is transmitted to the worker's mobile terminal (step S32). At this time, a map of the field may be displayed on the display of the portable terminal to indicate the position where the abnormality has occurred.
The worker goes to the abnormality occurrence position designated on the map or the like on the display of the portable terminal and confirms the abnormality. If the abnormality reported by the abnormality monitoring / diagnosis support system 6 has occurred, a confirmation input is made to the abnormality monitoring / diagnosis support system 6 (step S33).
[0060]
The abnormality monitoring / diagnosis support system 6 that has received the confirmation information transmits information related to the abnormality (including the occurrence of the abnormality, the position where the abnormality has occurred, and the content of the abnormality) to the unsteady driving support system (step S34). Thereafter, the unsteady driving support system provides information to the worker according to the content of the abnormality. In this case, the unsteady operation support system starts a pump switching program for switching the pump 122 in which an abnormality has occurred to another pump 123 (step S35), and passes operation information necessary for pump switching through the portable terminal. Provide to workers.
[0061]
First, the unsteady operation support system designates a field device necessary for switching the pump 122 to the pump 123, and instructs confirmation (step S36).
The operator confirms the positions of the main valve 121, the pump 122, and the pump discharge valve 124 of the kerosene raw material tank 120, confirms that there is no leakage or abnormal appearance, and operates the confirmation key. The end of confirmation of these field devices is input to the unsteady operation support system (step S37). The on-site equipment is confirmed by the operator reading the identification information of the IC chip by bringing the reading unit of the portable terminal close to the IC chip. In this case, the switching pump 123 and the pump discharge valve 125 of the pump 123 are confirmed.
[0062]
The unsteady operation support system that has received the confirmation information drives the pump 123 via the management device 2 (step S38).
The unsteady operation support system instructs the operator to confirm that the pump 123 has been driven and whether there is any abnormality such as abnormal noise or vibration in the pump 123 (step S39). If the pump 123 starts to drive normally and no abnormality is recognized, the operator inputs confirmation and transmits it to the unsteady driving support system (step S40).
The unsteady operation support system that has received the confirmation information instructs to open the pump discharge valve 125 of the pump 123 (step S41).
[0063]
The operator opens the pump discharge valve 125 according to this instruction. And it confirms that there is no abnormality and inputs it to a non-stationary driving | operation assistance system (step S42). The unsteady operation support system that has received the confirmation information instructs the operator to close the pump discharge valve 123 of the pump 121 that has failed (step S43), and the worker closes the pump discharge valve 123 (step S44). ). Then, the confirmation is input to the unsteady driving support system. Thereafter, the unsteady operation support system stops the driving of the pump 121 via the management computer (step S45), and transmits a report to that effect to the abnormality monitoring / diagnosis support system 6. Thereafter, the abnormality monitoring / diagnosis support system 6 starts monitoring and diagnosing the pump 123 and the pump discharge valve 124.
This completes the switching from the pump 121 to the pump 123 (step S46).
[0064]
Although the preferred embodiments of the present invention have been described, the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.
For example, in the above-described embodiment, the IC chip is described as an example of the identification means for specifying the field device. However, if the identification information for specifying the field device can be held, the IC chip is used. Not limited to this, other types such as a bar code and a Carla code (matrix code) may be used.
Further, the present invention can unmanned the field by automating all operations of driving valves, pumps, and motors. In this case, a drive body such as a motor, solenoid, or actuator may be provided in a valve, pump, motor, or the like, and a drive control device for controlling the drive of the drive body may be connected to the communication line 7. And a drive control apparatus should just control the drive body of a specific field device by the command signal of an unsteady driving | operation automatic assistance system.
[0065]
【The invention's effect】
According to the present invention, the roles of the board man and the field man can be concentrated on the workers in the field, and a specific operation can be performed quickly and accurately without changing even a less experienced worker from a skilled worker. Will be able to do.
In addition, according to the present invention, each operation of the field device is performed by the drive body, and the drive control apparatus is controlled by the drive body, so that in the future, during the unsteady operation, It is possible to fully automate the operation.
[Brief description of the drawings]
FIG. 1 is a block diagram illustrating a configuration of a driving operation system according to an embodiment of the present invention.
FIG. 2 is a diagram for explaining identification means for identifying field equipment provided in a field.
FIG. 3 is a diagram illustrating an example of display contents displayed on the display of the mobile terminal device.
FIG. 4 is a block diagram illustrating the configuration of an abnormality monitoring / diagnosis support system according to an embodiment.
FIG. 5 is an example of converting highly random data into regular data by chaos attractor theory, and FIG. 5 (a) is a synthesized waveform obtained by synthesizing acoustic data from a plurality of microphones provided in a field. FIG. 5B shows a waveform having a law after being transformed by the chaotic attractor theory.
6 is an example of a case where a change is made to the synthesized waveform of FIG. 5 and the waveform after conversion, and FIG. 6A shows a case where new sound source acoustic data is added to the synthesized waveform of FIG. FIG. 6B shows the synthesized waveform in this case, which is obtained by converting the waveform of the acoustic data in FIG. 6A by the chaotic attractor theory.
7A to 7C show acoustic data waveforms of three microphones having a large waveform change rate among a plurality of omnidirectional microphones in the field, and FIG. These are the figures explaining the procedure which pinpoints the position of a new sound source using such acoustic data.
FIG. 8A is a diagram showing a specific area in the furnace to be imaged, and FIG. 8B is an image obtained by photographing the specific area in FIG. 8A with an infrared camera. FIG. 8C is a schematic diagram of a database in which normal temperature distribution patterns are accumulated, which is color-coded into a plurality of temperature patterns based on an image.
FIG. 9 is a flowchart for explaining the operation of the driving operation support system in this embodiment, and explains an operation procedure when the raw material is switched from the light oil raw material to the kerosene raw material.
FIG. 10 is a flowchart for explaining the operation of the driving operation support system according to this embodiment, and explains an operation procedure when an abnormality occurs in a pump of a kerosene raw material piping system.
FIG. 11 is a schematic diagram illustrating the configuration of a kerosene / light oil desulfurization plant.
FIG. 12 is a diagram for explaining a cooperative operation between a board man and a field man in the desulfurization plant of FIG. 11;
FIG. 13 is a flowchart illustrating an example of cooperation of operations by a board man and a field man according to a conventional example of the present invention.
FIG. 14 is a flowchart showing an example of cooperation of operations by a boardman and a fieldman when an abnormality occurs according to the conventional example of the present invention.
[Explanation of symbols]
1 Driving support system
2 management devices
3 Mobile terminal devices
3a display
3b Reading unit
5 Unsteady driving automatic support system
6 Abnormality monitoring / diagnosis support system
7 Communication line
8a-8c IC chip

Claims (10)

A driving operation support system for supporting various operations performed by workers in fields such as plants and factories,
An individual device monitoring device for monitoring the status of individual devices in the field;
A wide area monitoring device for monitoring the state of a part or the whole of the field;
Analyzing data input from the individual device monitoring device and the wide area monitoring device, an abnormality monitoring / diagnosis support unit for supporting detection and diagnosis of an abnormality,
In the field, an operator terminal device that provides information on a specific operation to the operator,
The abnormality monitoring / diagnosis support unit and the worker terminal device are communicably connected, and the specific operation to be performed by the worker is determined based on the determination of the abnormality monitoring / diagnosis support unit, and is set in advance. A driving operation support system in a plant or the like, comprising: a driving operation support unit that transmits information related to the specific operation from operation data to the worker terminal device. A driving operation support system for supporting various operations performed by workers in fields such as plants and factories,
An individual device monitoring device for monitoring the status of individual devices in the field;
A wide area monitoring device for monitoring the state of a part or the whole of the field;
Analyzing data input from the individual device monitoring device and the wide area monitoring device, an abnormality monitoring / diagnosis support unit for supporting detection and diagnosis of an abnormality,
Drive means for driving each of the field devices in the field, and a drive control device for controlling the drive of the drive means;
The abnormality monitoring / diagnosis support unit and the drive control device are communicably connected to each other, and based on the determination of the abnormality monitoring / diagnosis support unit, predetermined operation information from preset operation data is transmitted to the drive control device. A driving operation support system in a plant or the like, characterized by comprising: The operation support system in a plant or the like according to claim 1 or 2, wherein an identification unit is provided in each of the field devices, and the field device is specified by reading identification information of the identification unit. The operator terminal device is provided with a reading unit that reads the identification information of the identification unit, and the field device included in the information transmitted from the driving operation support unit matches the field device specified by the identification information. 4. The operation support system for a plant or the like according to claim 3, further comprising a determination unit that determines whether or not there is any. The wide area monitoring device transmits data collected from a plurality of sensors provided at predetermined positions in the field to the abnormality monitoring / diagnosis support unit, and the abnormality monitoring / diagnosis support unit is based on the data. The operation support system in a plant or the like according to any one of claims 1 to 4, wherein abnormality detection, abnormality occurrence position, and abnormality content are determined. The abnormality monitoring / diagnosis support unit converts random data into data having regularity using a method of chaos attractor theory, and detects the abnormality based on a change in the data. The operation support system in the plant etc. of 5. The abnormality monitoring / diagnostic support unit uses a pattern recognition technique based on neural network processing to compare a normal state pattern prepared in advance with a pattern obtained from data transmitted from the field, and this comparison The operation support system in a plant or the like according to claim 5 or 6, wherein the abnormality is detected based on a result. The abnormality monitoring / diagnosis support unit performs detection of the abnormality, determination of an abnormality occurrence position, and determination of abnormality content based on data input from both the individual device monitoring device and the wide area monitoring device. An operation support system for a plant or the like according to any one of claims 1 to 7. The driving operation support unit includes information related to other operations excluding an operation when an abnormality occurs, and transmits information related to the other operations to the worker terminal and / or the drive control device. The operation support system in the plant etc. in any one of 1-8. When providing operation information to the worker via the worker terminal device, the driving operation support unit displays information on the display unit of the worker terminal using characters, symbols, figures, or a combination thereof. Alternatively, the operation support system in a plant or the like according to any one of claims 1 to 9, wherein the information is provided to the worker by voice.

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