JP2009157550A - Plant operation support system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To detect the abnormality of a plant based on an estimated value to be obtained by simulation following up the operation of the plant with high precision. <P>SOLUTION: The plant operation support system using a plant simulator for performing simulation following up the operation of an actual plant by using a plant model showing the operation of the actual plant is characterized in that whether or not the value of an adjustment parameter adjusted based on a measured value in the actual plant and an estimated value obtained by simulation by the plant simulator is determined within a predetermined allowable range by using the plant simulator for showing the state of the actual plant in a real time based on the measured value of the actual plant, thereby detecting the abnormality of the operating state of the actual plant. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a plant operation support system that performs a simulation that follows plant operation using a plant model that represents the operation of the plant, and more particularly to abnormality detection.

  Conventionally, plant state quantities such as temperature, flow rate, and pressure obtained from field devices such as sensors, actuators, and controllers installed in actual plants (hereinafter referred to as plants) such as chemical, petroleum, gas, and chemicals (hereinafter, measured) By simulating in parallel with the plant operation using a model formula (hereinafter referred to as the plant model) that appropriately formulates the physical and chemical phenomena for simulating the plant operation. There is a plant operation support system for estimating an estimated value of a state quantity of a plant by estimating a quantity of the state, such as temperature and pressure, of a plant that cannot be measured in real time.

  In addition, this plant operation support system detects an abnormality by assuming that there is some abnormality when the measured value of the field device of the plant and the estimated value by simulation exceed a predetermined allowable error. .

  Prior art documents related to a plant operation support system that performs a simulation to follow the operation of a plant using a conventional plant model include the following.

JP-A-6-222191 JP-A-9-134213 JP-A-10-214112 JP 2005-332360 A

  FIG. 4 is a configuration block diagram of a conventional plant operation support system. Field equipment (not shown) is installed in the plant 1, and actual values such as flow rate and temperature obtained by each field equipment and operation amounts and set values of the field equipment are transmitted to the plant operation support system 2 in real time via a network (not shown). It has a function to transmit.

  The plant operation support system 2 includes a plant simulator 21, a display control unit 22, and a display unit 23 such as an LCD (Liquid Crystal Display). The plant simulator 21 includes a plant model in which physical and chemical phenomena for simulating the operation of the plant 1 are appropriately expressed, and has a simulation function for estimating the operation of the plant 1. The display control unit 22 has a display control function for controlling screen display such as a graph.

  The plant 1 is connected to a plant simulator 21, and the plant simulator 21 is connected to a display control unit 22. The display control unit 22 is connected to the display unit 23.

  In FIG. 4, the plant 1 transmits to the plant simulator 21 an actual measurement value obtained by a field device in the plant 1, an operation amount of the field device, a set value, and the like. The plant simulator 21 performs a simulation using a plant model based on the actual measurement value, the operation amount, and the set value.

  The plant simulator 21 performs a simulation in real time in parallel with the actual operation of the plant 1 using the plant model based on the actual measurement value from the plant 1 to obtain an estimated value of the state quantity of the plant 1. Further, the plant simulator 21 outputs an actual measurement value and an estimated value obtained by simulation to the display control unit 22.

  The display control unit 22 displays, on the display unit 23, a trend graph showing the actual measurement value and the estimated value in time series based on the actual measurement value and the estimated value from the plant simulator 21. As a result, the operator can grasp the state of the plant 1 based on the graph of the display unit 23. Further, the display control unit 22 displays an estimated value by the plant simulator 21 at a location that cannot be actually measured in the plant 1 on the display unit 23.

  As described above, the plant operation support system 2 can grasp the internal state of the plant by performing simulation in real time in parallel with the actual operation of the plant 1 based on the actually measured value from the plant 1.

  By the way, the plant operation support system 2 detects an abnormality in the operation state of the plant 1.

  For example, the plant operation support system 2 performs display control assuming that an abnormality has been detected when a deviation greater than a predetermined allowable error occurs between an actual measurement value of a field device (not shown) of the plant 1 and an estimated value on the plant simulator 21. The unit 22 is controlled to display the fact on the display unit 23 to notify the operator of the plant operation support system 2.

  On the other hand, the model expression of the plant model that represents the plant operation is not an approximation of the plant operation, but is an approximate expression. Therefore, even if a simulation is performed using this plant model, simulation values and actual measurement values are used. May not match.

  For this reason, the plant simulator 21 includes a parameter adjustment unit having an adjustment function that sequentially and automatically adjusts the value of a parameter (hereinafter referred to as an adjustment parameter) in the model formula of the plant simulator 21 based on the estimated value obtained by itself. A simulation that follows the movement of the controlled object with high accuracy is performed.

  The parameter adjustment unit compares the actual value acquired from the plant 1 with the estimated value calculated and estimated by the plant simulator 21 to determine whether the error between the actual value and the estimated value is within an allowable range. When it is determined that it is not within the range, the adjustment parameter is adjusted and applied to the plant model of the plant simulator 21 to perform a simulation that follows the operation of the plant 1 with high accuracy.

  However, when the parameter adjustment unit adjusts the adjustment parameter, there is no problem that the deviation between the measured value of the plant and the estimated value by the plant simulator does not occur, so that the abnormality cannot be detected.

  In addition, in the case of a plant simulator in which parameters are fixed and adjustments are not performed, the estimated values obtained by the simulator have a large error from the actual measured values in the first place, and the plant simulator does not check whether the plant operating state is abnormal. There is a problem that it is difficult to determine whether it is complete, and it is difficult to detect abnormality.

  The present invention solves the above-mentioned problems, and an object of the present invention is to detect an abnormality of the plant based on an estimated value obtained by a simulation that follows the operation of the plant with high accuracy.

In order to achieve such a problem, the invention according to claim 1 of the present invention is:
In a plant operation support system using a plant simulator that performs a simulation to follow the operation of an actual plant using a plant model representing the operation of the actual plant,
Using a plant simulator that reproduces the state of the actual plant in real time based on the actual measured value of the actual plant,
Determining whether the value of the adjustment parameter adjusted based on the actual measured value in the actual plant and the estimated value obtained by simulation by the plant simulator is within a predetermined allowable range;
An abnormality in the operating state of the actual plant is detected.

The invention according to claim 2
A simulation is performed in parallel with the operation of the actual plant using a plant model based on an actual measurement value from the actual plant, and an adjustment parameter that is sequentially and automatically adjusted based on an estimated value obtained by the simulation is applied to the plant model. A plant simulator that reduces the error between the measured value of the plant and the estimated value of the plant simulator, and faithfully reproduces the state of the actual plant based on the actual measured value of the actual plant;
And an abnormality detecting unit for determining whether or not the value of the adjusted adjustment parameter is within a predetermined allowable range.

The invention described in claim 3
In the plant operation support system according to claim 1 or 2,
The abnormality detection unit
An abnormality detection table that stores an allowable upper limit value and an allowable lower limit value for each adjustment parameter;
Comparing the adjusted parameter value with the allowable upper limit value and the allowable lower limit value stored in the abnormality detection table, the abnormality determining unit is configured to determine whether or not the operation state of the plant is abnormal. It is characterized by.

The invention according to claim 4
The plant operation support system according to claim 3, wherein
The abnormality determination unit
When the value of the adjusted adjustment parameter is larger than the allowable upper limit value or smaller than the allowable lower limit value, it is determined that the operation state of the actual plant is abnormal.

The invention according to claim 5
In the plant operation support system according to any one of claims 1 to 4,
A communication unit that receives actual measurement values from the actual plant;
A simulation is performed in parallel with the operation of the actual plant using the plant model based on the actual measurement value received via the communication unit, and the actual plant measurement value and the plant simulator are estimated based on the estimated value obtained by the simulation. The adjustment parameter is sequentially and automatically adjusted so as to reduce the error of the estimated value and applied to the plant model, and it is determined whether or not the value of the adjusted adjustment parameter is within a predetermined allowable range, And an arithmetic control unit that determines that the operating state of the actual plant is abnormal when the value of the adjusted adjustment parameter is outside the allowable range.

  According to the present invention, an abnormality of a plant is detected based on an estimated value obtained by a simulation that follows the operation of the plant with high accuracy.

  FIG. 1 is a functional block diagram of a plant operation support system according to the present invention. In FIG. 1, field equipment (not shown) is installed in the plant 3, and a plant operation support system in real time via a network (not shown) showing actual values such as flow rate and temperature obtained by each field equipment, operation amounts and setting values of the field equipment. 4 has a function to transmit.

  The plant operation support system 4 includes a plant simulator 41, a display control unit 42 having a display control function for controlling screen display such as a graph, a display unit 43 such as an LCD (Liquid Crystal Display), and an abnormality detection unit 44. The plant simulator 41 has a plant model pre-modeled by mathematical formulas for simulating the operation of the plant 3, and calculates the operation of the plant 3 based on the actual measurement value, the operation amount, and the set value from the plant 3. It has a simulation function to estimate.

  The plant simulator 41 includes a parameter adjustment unit 41A. The parameter adjustment unit 41A has an adjustment function that sequentially and automatically adjusts the value of the adjustment parameter in the plant model based on the estimated value of the operation state of the plant 3 calculated and estimated by the plant simulator 41.

  The parameter adjustment unit 41A compares the actual measurement value acquired from the plant 3 with the estimated value obtained by the plant simulator 41, and determines whether or not the error between the actual measurement value and the estimated value is within a predetermined allowable range. If it is determined that it is not within the allowable range, the adjustment parameter is adjusted so as to reduce the error between the measured value of the plant 3 and the estimated value of the plant simulator 41, and is applied to the plant model of the plant simulator 41.

  The abnormality detection unit 44 has an abnormality detection function for detecting a plant abnormality based on the adjustment parameter value of the parameter adjustment unit 41A. In addition, the abnormality detection unit 44 compares the value of the adjustment parameter with a predetermined allowable upper limit value and allowable lower limit value to determine whether or not the operation state of the plant 3 is abnormal, and for each adjustment parameter. It has an abnormality detection table 44B that stores predetermined allowable upper limit values and allowable lower limit values.

  By the way, it is known that within the normal operating conditions of the plant, the fluctuation width of the adjustment parameter value by the parameter adjustment of the parameter adjustment unit 41A falls within a certain region for each normal adjustment parameter.

  For this reason, an allowable upper limit value and an allowable lower limit value are determined in advance for each adjustment parameter, and it is determined whether the adjusted adjustment parameter value is within an allowable range from the allowable upper limit value to the allowable lower limit value. Determines whether it is abnormal.

  The allowable upper limit value and the allowable lower limit value of the adjustment parameter can be grasped by an experiment in the plant 3 or the like when the plant model is created. Further, the operation state of the plant 3 in a case where an abnormality occurs in the plant 3 on the plant simulator 41 or a failure in the equipment in the plant 3 is estimated in advance by simulation, and the allowable upper limit value and the allowable lower limit value of the adjustment parameter are set. It may be something to grasp.

  The plant 3 is connected to a plant simulator 41, and the plant simulator 41 is connected to a display control unit 42 and an abnormality detection unit 44. The abnormality detection unit 44 is connected to the display control unit 42, and the display control unit 42 is connected to the display unit 43.

  The plant operation support system 4 includes an arithmetic control unit (not shown) (for example, a CPU (Central Processing Unit)) that controls various functions and operations of each unit, a communication unit that performs communication between the plant and each device, an OS (Operating System), From hardware such as programs and applications to operate as devices, data used when executing these programs, ROM (Read Only Memory) for storing various information, and storage units such as RAM (Random Access Memory) Each part is connected to each other by a bus.

  The operation control unit of the plant operation support system 4 starts up the OS stored in the storage unit, reads out and executes the program stored on the OS, for example, the operation control unit is a program. Are read out and executed to control each function (parts) such as the plant simulator 41, the display control unit 42, and the abnormality detection unit 44, and perform a system-specific operation.

  At this time, the storage unit expands the program or application executed by the arithmetic control unit in the program storage area, and temporarily stores the input data or data such as processing results generated when the program or application is executed in the work area. To do.

  The operation in which the calculation control unit of the plant simulator 41 reads out and executes a program or application stored in the storage unit to control each unit or each function will be omitted below.

  2 is an operation flow diagram for explaining the operation of FIG. 1, and FIG. 3 is an example of an abnormality detection table. In step SP1 of FIG. 2, the plant simulator 41 acquires an actual measurement value obtained by a field device in the plant 3, and performs a simulation using a plant model based on the acquired actual measurement value.

  In step SP2, the parameter adjustment unit 41A compares the measured value acquired from the plant 3 with the estimated value calculated and estimated by the plant simulator 41, and determines whether or not the error between the measured value and the estimated value is within an allowable range. Judging. If the parameter adjustment unit 41A determines that the error between the actually measured value and the estimated value is not within the allowable range, the error between the actually measured value and the estimated value is within the allowable range or until the error is between the estimated value and the estimated value. Adjust the adjustment parameters up to and apply to the plant model.

  In step SP3, the abnormality determination unit 44A compares the value of the adjustment parameter adjusted by the parameter adjustment unit 41A with the allowable upper limit value and the allowable lower limit value stored in the abnormality detection table 44B, and the operation state of the plant 3 is abnormal. It is determined whether or not.

  In other words, the abnormality determination unit 44A determines whether or not the value of the adjustment parameter is within a predetermined allowable range, and grasps whether or not the operation state of the plant 3 is abnormal. The abnormality determination unit 44A determines that the operation state of the plant 3 is abnormal when the value of the adjustment parameter is larger than the allowable upper limit value or smaller than the allowable lower limit value, that is, outside the allowable range.

  If the abnormality detection unit 44 determines that the operation state of the plant 3 is outside the allowable range and is abnormal, the process proceeds to step SP4. When it is determined that the parameter value is not outside the allowable range (within the allowable range) and the operation state of the plant 3 is not abnormal, the process returns to step SP2.

  For example, the abnormality determination unit 44A sets the adjustment parameter value acquired from the plant simulator 41 (for example, the adjustment parameter 1 value: 110) and the adjustment parameter stored in the abnormality detection table 44B as shown in FIG. The allowable upper limit value (for example, allowable upper limit value of adjustment parameter 1: 100) and the allowable lower limit value (for example, allowable lower limit value of adjustment parameter 1: 0) are compared.

  The abnormality determination unit 44A determines that the operation state of the plant 3 is abnormal because the value “110” of the adjustment parameter 1 is larger than the allowable upper limit value “100” as shown in FIG.

  In step SP4, the abnormality determination unit 44A displays on the display unit 43 that the operation state of the plant 3 is abnormal via the display control unit 42, or abnormally occurs in an apparatus or operator outside the plant operation support system. Transmit alarm output including detection results.

  As described above, the plant operation support system according to the present invention is adjusted by adjusting the adjustment parameter based on the estimated value obtained by the plant simulator so as to reduce the error between the measured value of the plant and the estimated value of the plant simulator. By determining whether or not the value of the adjustment parameter is within a predetermined allowable range, an abnormality in the operation state of the plant can be detected.

  In the above-described embodiment, the abnormality detection table 44B stores the allowable upper limit value and the allowable lower limit value of each adjustment parameter as illustrated in FIG. 3A. However, the present invention is not limited to this. In the case where some or all of the operating conditions such as the temperature, pressure, and inlet composition of the plant 3 are known, the value that each adjustment parameter can take normally is limited to a narrower range, The allowable upper limit value and the allowable lower limit value of each adjustment parameter may be set in consideration of the operation conditions of the plant 3. Further, an allowable upper limit value and an allowable lower limit value of each adjustment parameter may be stored as a function taking into account the plant operating conditions.

  For example, as shown in FIG. 3B, the abnormality detection table 44B has operating conditions such as the pressure (P), temperature (T), and flow rate (F) of the plant 3 for each adjustment parameter (for example, the adjustment parameter 2). Based on the above, an allowable upper limit value (for example, 1.00E + 03 when F <100, 1.00E + 04 when F> 100) and an allowable lower limit value (for example, 1.00E + 05) are set and stored in accordance with changes in operating conditions.

  For example, as shown in FIG. 3B, the abnormality detection table 44B considers the pressure (P), temperature (T), flow rate (F), etc. of the plant 3 for each adjustment parameter (for example, the adjustment parameter 3). An allowable upper limit value (for example, “(P−1) * T * 300”) and an allowable lower limit value (for example, “(P + 1) * T * 400”) are stored as functions.

  For this reason, the abnormality can be detected in more detail by setting the allowable upper limit value and the allowable lower limit value of each adjustment parameter in consideration of the operation conditions of the plant 3.

  In the above embodiment, when the parameter adjustment unit 41A determines in step SP2 in FIG. 2 that the difference between the actually measured value acquired from the plant 3 and the estimated value calculated and estimated by the plant simulator 41 is not within the allowable range, the actually measured value. The adjustment parameter is adjusted until the estimated value matches the estimated value or the difference between the estimated value and the actually measured value is within the allowable range. If the difference cannot be within the allowable range, it may be determined unconditionally as abnormal. As described above, when the estimated value and the actually measured value cannot be matched, or the difference cannot be within the allowable range, the process may move to step SP4.

  Also, the above embodiment records fluctuations in operating conditions and adjustment parameter values during plant operation, and collects, stores, and learns each data such as adjustment parameter values and plant operating conditions during non-failure or failure. Thus, the accuracy of the abnormality detection table may be increased.

  In the above-described embodiment, the abnormality detection table 44B stores the allowable upper limit value and the allowable lower limit value of each adjustment parameter as illustrated in FIG. 3A, but is not limited thereto. An upper management value and a lower management value may be set between the allowable upper limit value and the allowable lower limit value of each adjustment parameter.

  For example, when the value of the adjustment parameter (for example, adjustment parameter 1) exceeds these management values (lower management value: 20, upper management value: 80) as shown in FIG. It is determined that the operating state of the vehicle is becoming abnormal, an abnormality warning is displayed on the display unit 43 via the display control unit 42, and an alarm including an abnormality detection result is displayed on an external device or operator of the plant operation support system. Can be dealt with before it becomes abnormal.

  In the above-described embodiment, the abnormality detection table 44B stores the allowable upper limit value and the allowable lower limit value of each adjustment parameter as illustrated in FIG. 3A, but is not limited thereto. When the relationship between the adjustment parameters can be defined from phenomena that can be theoretically determined such as the mass balance and the heat balance (for example, in FIG. 3C, the relationship between the adjustment parameter 1 and the adjustment parameter 3 can be defined). And an allowable upper limit value (for example, allowable upper limit value “adjustment parameter 3 = adjustment parameter 1 * F + 10”) and an allowable lower limit value (for example, allowable upper limit value “adjustment parameter 3 = Adjustment parameter 1 * F-10 ")), upper limit management value and lower limit management value are defined, and when the parameter exceeds these allowable errors, it is determined that there is an abnormality Or it may be of.

  In addition, the plant operation support system 4 of the above-described embodiment is configured by functions of the plant simulator 41, the parameter adjustment unit 41A, the abnormality detection unit 44, and the like, but is not particularly limited thereto. As long as the support system 4 can operate with each function, the plant simulator 41, the parameter adjustment unit 41A, and the abnormality detection unit 44 may be configured by independent devices and connected to each other.

  Specifically, the plant simulator 41, the parameter adjustment unit 41A, and the abnormality detection unit 44 are each an arithmetic control unit (for example, a CPU) that controls various functions (not shown) and operations of each unit, a communication unit that communicates between the devices, It consists of hardware such as a memory or a storage unit such as a RAM or ROM that stores programs and applications for operating as an OS and each device, data used when executing these programs, and various information, etc. It may be composed of independent devices that are connected to each other.

  In this case, the calculation control unit of the plant simulator 41, the parameter adjustment unit 41A, and the abnormality detection unit 44 activates the OS stored in the storage unit, and reads and executes the program stored on the OS. Each device or each part is controlled and an operation specific to each device or each part is performed. At this time, the storage unit expands the program or application executed by the arithmetic control unit in the program storage area, and temporarily stores the input data or data such as processing results generated when the program or application is executed in the work area. You may do.

It is a functional block diagram of the plant operation assistance system concerning the present invention. It is an operation | movement flowchart explaining the operation | movement of FIG. It is an example of an abnormality detection table. It is a block diagram of a conventional plant operation support system.

Explanation of symbols

1, 3 Plant 2, 4 Plant operation support system 21, 41 Plant simulator 22, 42 Display control unit 23, 43 Display unit 41A Parameter adjustment unit 44 Abnormality detection unit 44A Abnormality determination unit 44B Abnormality detection table

Claims (5)

In a plant operation support system using a plant simulator that performs a simulation to follow the operation of an actual plant using a plant model representing the operation of the actual plant,
Using a plant simulator that reproduces the state of the actual plant in real time based on the actual measured value of the actual plant,
Determining whether the value of the adjustment parameter adjusted based on the actual measured value in the actual plant and the estimated value obtained by simulation by the plant simulator is within a predetermined allowable range;
A plant operation support system that detects an abnormality in the operation state of the actual plant. A simulation is performed in parallel with the operation of the actual plant using a plant model based on an actual measurement value from the actual plant, and an adjustment parameter that is sequentially and automatically adjusted based on an estimated value obtained by the simulation is applied to the plant model. A plant simulator that reduces the error between the measured value of the plant and the estimated value of the plant simulator, and faithfully reproduces the state of the actual plant based on the actual measured value of the actual plant;
The plant operation support system according to claim 1, further comprising an abnormality detection unit that determines whether or not the value of the adjusted adjustment parameter is within a predetermined allowable range. The abnormality detection unit
An abnormality detection table that stores an allowable upper limit value and an allowable lower limit value for each adjustment parameter;
Comparing the adjusted parameter value with the allowable upper limit value and the allowable lower limit value stored in the abnormality detection table, the abnormality determining unit is configured to determine whether or not the operation state of the plant is abnormal. The plant operation support system according to claim 1 or 2, characterized by the above-mentioned. The abnormality determination unit
The plant operation according to claim 3, wherein when the value of the adjusted adjustment parameter is larger than the allowable upper limit value or smaller than the allowable lower limit value, the operation state of the actual plant is determined to be abnormal. Support system. A communication unit that receives actual measurement values from the actual plant;
A simulation is performed in parallel with the operation of the actual plant using the plant model based on the actual measurement value received via the communication unit, and the actual plant measurement value and the plant simulator are estimated based on the estimated value obtained by the simulation. The adjustment parameter is sequentially and automatically adjusted so as to reduce the error of the estimated value and applied to the plant model, and it is determined whether or not the value of the adjusted adjustment parameter is within a predetermined allowable range, 5. An arithmetic control unit that determines that the operating state of the actual plant is abnormal when the value of the adjusted adjustment parameter is outside the allowable range. 6. Plant operation support system.

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