JP2010044780A - Method and system for analyzing operating condition - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and system for analyzing an operation condition. <P>SOLUTION: The system for analyzing an operation condition includes: an information collecting means for collecting information on the state of a device controlled by a distributed control system or the operation to the device; an index value calculating means for calculating an index value, which is related to the availability of the device and representing a period longer than an information collecting interval in the information collecting means, by calculation based on the information collected by the information collecting means; and an index value storage means for storing the index value calculated by the index value calculating means. An analyzing part includes: an index value collecting means for collecting the index values from the index value storage means of the plurality of devices which are installed to a plurality of job sites; a normalizing means for normalizing the index values collected by the index value collecting means; and a comparing and analyzing means for comparing and analyzing the availability of the devices in the plurality of job sites, based on the index values normalized by the normalizing means. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an operation state analysis method and an operation state analysis system for analyzing an operation (use) state of an apparatus introduced into a production site.

Various devices (various devices and various systems) such as field devices such as sensors, analyzers, and regulating valves, distributed control systems, network control systems, safety measurement systems, equipment management systems, plant information management systems, and operation management systems Developed and manufactured by specific developers and manufacturers, these devices are installed at various customer production sites (hereinafter simply referred to as sites).
JP 2004-21712 A

However, at present, these apparatuses do not have a function of calculating and displaying, as an index value, how effectively the function provided by the apparatus itself is used. For example, in a distributed control system whose main function is a control function and a monitoring function, an index value indicating whether the control function is effectively utilized (for example, a time integrated value of deviation for each PID control loop, automatic control, etc. There is no function to calculate and display the PID control loop to be closed.
There is also no function for calculating and displaying an index value (for example, an integrated value of the number of screen touch operations per board operator) indicating whether or not the monitoring function is effectively utilized.

  For this reason, customers cannot easily grasp how effectively the functions of each device they have purchased and used are being used, and either manually or for calculation, You need to create your own application. In addition, since some of such index values need to be calculated using internal data hidden by each device, customers cannot calculate such index values themselves. In this way, it is not easy to know whether the functions of the equipment that you have purchased and used are being used effectively, so the customer cannot feel the need to improve the utilization level. There is a possibility that the function of the apparatus cannot be fully exerted and a production loss or the like has occurred. In addition, data from other companies that use similar devices cannot be obtained. At present, there is no company that provides a comparative analysis service on the degree of utilization, and comparison analysis with competitors is not possible.

  Also, in order to carry out an effective analysis, various information on the device provider side that develops, manufactures, and sells the device is necessary. There is also a circumstance that the effect cannot be obtained.

  An object of the present invention is to provide an operation state analysis method and an operation state analysis system that make it possible to easily grasp the degree of utilization by analyzing the operation state of the apparatus.

The operation status analysis system of the present invention is an operation status analysis system in which an analysis unit analyzes an operation status of a device connected to a distributed field control system, wherein each of the devices is information handled by the distributed control system. And based on the information collected by the information collection means, the information collection means for collecting information related to the control state of the apparatus by the distributed field control system or the operation to the apparatus by the distributed field control system By means of calculation, an index value calculation means for calculating an index value as a value relating to the utilization degree of the apparatus and representing a period longer than the information collection interval in the information collection means, and the index value calculation means Index value storage means for storing the calculated index value, and the analysis unit includes a plurality of Index value collection means for collecting the index values from the index value storage means of the plurality of devices introduced to the site; and normalization means for normalizing the index values collected by the index value collection means; Comparative analysis means for performing a comparative analysis of the utilization of the apparatus between the plurality of sites based on the index value normalized by the normalization means;
It is characterized by comprising.
According to this operating state analysis system, since the comparative analysis of the device utilization is performed based on the information handled by the distributed control system, the device utilization can be easily grasped.

  The information may include a control value that is a control target in the distributed field control system, and the index value may include an integrated value of a deviation amount from a set value of the control value.

  The index value may include a time ratio during which a control value that is a control target in the distributed field control system is automatically controlled.

The information may include a control value that is a control target in the distributed field control system, and the index value may include a time ratio during which the control value is controlled within a predetermined range.

  The index value may include a frequency of screen expansion operations in the distributed field control system.

  The index value may include a frequency of manual operation in the distributed field control system.

  The analysis unit reports, as a comparison analysis result by the comparison analysis unit, a report indicating the utilization of the device on the comparison with the utilization of the devices constituting the other distributed field control system. You may provide the report transmission means to transmit toward.

  The apparatus may include receiving means for receiving the report transmitted by the report transmitting means.

  The normalization means may normalize the index value using another index value.

  The normalizing means may normalize the index value based on a situation of a plant related to the device.

  The device may be a control device that controls a field device.

  The device may be a field device.

  The index value collecting means may collect the index values from the storage means of a plurality of the devices via a public line.

The operation status analysis method according to the present invention is an operation status analysis method in which an analysis section analyzes an operation status of a device connected to a distributed field control system, and includes information handled by the distributed control system in each of the devices. Based on the information collected by the step of collecting information related to the control state of the device by the distributed field control system or the operation of the device by the distributed field control system, and the step of collecting the information Calculating and holding an index value as a value representing a period longer than the collection interval of the information in the step of collecting the information by a calculation, In the analysis unit, the index value from a plurality of the devices introduced into a plurality of the sites. Collecting the index value, normalizing the index value collected by the step of collecting the index value, and the apparatus between the plurality of sites based on the index value normalized by the normalizing step Performing a comparative analysis of the degree of utilization.
According to this operation status analysis method, since the comparative analysis of the utilization of the apparatus is performed based on the information handled by the distributed control system, the utilization of the apparatus can be easily grasped.

  According to the operation status analysis system of the present invention, since the comparative analysis of the device utilization is performed based on the information handled by the distributed control system, the device utilization can be easily grasped.

  According to the operation state analysis method of the present invention, since the comparative analysis of the utilization of the apparatus is performed based on the information handled by the distributed control system, the utilization of the apparatus can be easily grasped.

  Hereinafter, with reference to FIGS. 1-3, one Embodiment of the driving | running condition analysis method by this invention is described.

  FIG. 1 is a diagram showing the concept of the driving situation analysis method of the present embodiment.

  As shown in FIG. 1, in this embodiment, the operating status of the apparatuses 10, 10,. The device provider 2 collects index values necessary for analyzing the effective utilization of the devices 10, 10,... From the devices 10, 10,. At the same time, the index value is used to analyze the effective utilization of the device, and a report is created. The device provider 2 is, for example, a developer, manufacturer or seller of the devices 10, 10,.

  The analysis result of the effective utilization degree is notified to the customer of the apparatus as a report. The destination of the report is, for example, the customer who purchased each device 10, and the report is, for example, for each device 10, for each system including the device 10, for each site 1 such as a plant, or for each customer. The evaluation result about the effective utilization degree of the system including is shown.

  FIG. 2 is a block diagram functionally showing the configuration of the apparatus 10 and the report creation system applied to the driving situation analysis method of the present embodiment.

  As shown in FIG. 2, the apparatus 10 introduced into the site has an index value presentation function 10a and a report browsing function 10b.

  The device 10 includes, as elements constituting the index value presentation function 10a, an information collection unit 11 as an information acquisition unit that collects data that is the original data of the index value, and data to be collected by the information collection unit 11 in the device 10 An information definition unit 12 that is defined by tag names and the like used in the above, an index value calculation unit 13 that calculates an index value based on data collected by the information collection unit 11, and an index value storage that stores the calculated index value Unit 14 and an index value transmission unit 15 that transmits the stored index value in a timely manner.

  The device 10 includes, as elements constituting the report browsing function 10b, a report receiving unit 16 that receives a report, a report storage unit 17 that stores the received report, and a report browsing unit that browses the stored report 18 and a report WEB browsing unit 19 for browsing reports using the WEB service.

On the other hand, the device provider 2 has a report creation system 20.
A customer who has received permission from the device provider 2 may own the report creation system 20, or the device 10 may be provided with the report creation system 20.

  As shown in FIG. 2, the report creation system 20 includes an index value receiving unit 21 that receives an index value transmitted from the device 10, an index value storage unit 22 that stores the received index value, and a stored index. An index value analysis unit 23 as an analysis unit that performs a predetermined analysis using values, a support creation unit 24 that creates a report based on an analysis result in the index value analysis unit 23, and stores the created report A report storage unit 25 and a report transmission unit 26 that transmits the stored report in a timely manner are provided.

  FIG. 3 shows an example in which a part of the index value presentation function is provided outside the apparatus. In FIG. 3, the above-described index value presentation function is provided in the device 10A and the device 10B introduced into the plant 1A, and the index value is directly transmitted. In contrast, the apparatus 10C and the apparatus 10D are not provided with the above-described index value presentation function, and a part of the index value presentation function is configured by the external personal computer 4A and the personal computer 4B. Thus, the index value presentation function can be provided in an external device.

  The report browsing function may not be provided in the device 10 but may be provided in another device. In this case, the said report should just be transmitted toward an apparatus provided with a report browsing function. Further, the transmission destination or destination of the report is not limited, and may be presented to a presentation destination determined by a contract or the like.

  Next, operations of the apparatus 10 and the report creation system 20 will be described.

The information collection unit 11 of the apparatus 10 collects data according to the definition content of the information definition unit 12. The data to be collected includes process data, alarm messages, event messages, device internal data, user-defined data, and the like.
The internal data of the device is data that has no meaning to the customer as it is and is not disclosed to the customer. The internal data includes, for example, a screen ID indicating a screen switching state, a data quality code, the number of alarms being issued, and the like.
The user-defined code includes, for example, the plant hierarchical structure input by the user (customer) and the number of connected input / output devices.

  The information collection unit 11 actively collects data at regular intervals and passively collects data when an event occurs. The collection method varies depending on the type of data.

  The index value calculation unit 13 calculates various index values based on the data collected by the information collection unit 11. In addition, such calculation value integration processing is executed. The integrated value is used as a new index value (index value for each unit time).

  The index value storage unit 14 stores the index value in a predetermined cycle unit. As the cycle unit corresponding to each index value, for example, hourly, daily, weekly, yearly, operation shift (work shift) units, and batch units in a batch process are used.

  The index value transmission unit 15 transmits the index value stored in the index value storage unit 14 to the report creation system 20 at a predetermined cycle (daily, weekly, monthly, yearly, etc.). The Internet or other public lines or dedicated lines can be used as the index value transmission path.

  On the other hand, the index value receiving unit 21 of the report creation system 20 receives the transmitted index value. The index value storage unit 22 stores the received index value in a predetermined cycle unit. The cycle unit corresponding to each index value corresponds to the cycle unit at the time of storage in the index value storage unit 14.

  Instead of transmitting the index value by the index value transmission unit 15, the index value stored in the index value storage unit 14 can be given to the report creation system 20 by e-mail or by carrying a recording medium. In this case, the index value is stored directly in the index value storage unit 22.

  Next, the index value analysis unit 23 performs an analysis based on the index value stored in the index value storage unit 22.

Here, the comparative analysis is performed after normalizing the data that is the index value. As a result, more rational statistical processing of the index value or appropriate evaluation on the report is possible. Examples of elements (also index values) used for normalization include the following.
(1) Process unit or plant hierarchy.
(2) The number of input / output devices connected to the device 10 (the number of analog inputs, the number of analog outputs, the number of digital inputs, the number of digital outputs). The evaluation for these numerical values reflects, for example, the plant hierarchy and the monitoring area.
(3) Number of operation modes and types of operation modes.
(4) Number of alarm definitions. The evaluation for this numerical value reflects, for example, the plant hierarchy, the monitoring area, the importance of the alarm, and the alarm format.
(5) Number of PID loops. For example, in addition to the plant hierarchy and the monitoring area, the degree of complexity such as whether the loop is single or cascade is reflected in the evaluation for this numerical value.
(6) Number of APC loops.
(7) Number of operation shifts (number of work shifts).
(8) Number of board operators (number of operators for the monitoring terminal). The evaluation for this numerical value reflects, for example, the number of operation shifts (number of work shifts).

The index value can be selected as appropriate. However, from the viewpoint of evaluating RASIS (reliability, availability, maintainability, maintainability / completeness, confidentiality) as index values to be subjected to comparative analysis, for example, the following can be cited. These can be evaluated, for example, for each component, for each card (circuit unit), and for each monitoring device.
(1) Reliability
・ Average failure interval = operation time / number of failures / accuracy. For example, a time when the operation time / data quality code is other than “good” and no alarm is generated.
Factors that reduce reliability include, for example, poor installation environment, poor usage, poor product quality, and low calibration frequency.
(2) Availability
-Occupancy rate = average failure interval / (average failure interval + average repair time)
(3) Serviceability
Average repair time = repair time / number of failures Factors that reduce availability include, for example, poor service response, remote service bases, and poor maintenance staff skills.
(4) Integrity and integrity
Whether accidental or deliberate data destruction does not occur, and if it can be repaired. Whether there is exclusive control, error control, etc. Factors that deteriorate maintainability and integrity include, for example, lack of systems and measures.
(5) Security
Frequency of unauthorized access and information leakage. Factors that reduce confidentiality include lack of security measures and lack of employee morals.

From the viewpoint of controllability, for example, the following index values can be cited.
(6) The integrated value (every day) of the deviation from the set value (target value) of the control value for each control loop. Controller tuning failure, control loop design failure, process design failure, etc. are factors that lower the evaluation.
(7) Total time during which a specific control value (CV) is controlled by automatic control (not switched to manual) in one day. The fact that the control is unstable and the creation of a control loop that does not need to be controlled are factors that lower the evaluation.
(8) Total time during which the control value (CV) is in a controllable state during the day. Range over, instrument failure, communication failure, etc. caused by range cut and piping sizing are factors that lower the evaluation.
(9) Total time during which a specific control value (CV) is controlled by automatic control within a day and the value is within an allowable range corresponding to a set value or a set range. Controller tuning failure, control loop design failure, process design failure, etc. are factors that lower the evaluation. Computation is easier than in (6) above.

In addition, from the viewpoint of process monitoring work, the following index values can be cited.
(10) Number of screen expansions. This value corresponds to the frequency of work, and this value is calculated in units of shift time (working hours) of the operator.

In addition, the following index values can be cited from the viewpoint of alarm tracking and monitoring.
(11) Number of alarms that can be issued for each alarm importance. Defining alarms in the dark clouds is a factor that lowers the evaluation.
(12) Definition ratio for each alarm importance. Assigning a certain level of importance to an alarm is a factor that lowers the evaluation.
(13) Number of alarms per operator working time.
(14) Number of emergency alarms in one day.
(15) The number of alarms recovered without being recognized by the operator (no confirmation operation) during the day.
(16) Number of alarms that lasted for a long time during the day.
(17) Number of specific alarms that occurred multiple times during the day.

Furthermore, from the viewpoint of manual operation intervention during automatic control, the following index values can be cited.
(18) Number of manual operations. Calculated on a daily basis or for each operator shift. This evaluation is reduced when there are control loops that are difficult to control automatically.
(19) Number of intervention operations to set value (target value). Calculated on a daily basis or for each operator shift. This evaluation decreases when the operating condition change frequency is high, or when the operator repeats useless operations.
(20) The number of intervention operations to the alarm threshold. Calculated on a daily basis or for each operator shift. This evaluation decreases when the operating condition change frequency is high or when the alarm threshold is not optimized.

  Next, the report creation unit 24 (FIG. 2) creates a report for the customer based on the analysis result in the index value analysis unit 23, and the created report is stored in the report storage unit 25.

  The report transmission unit 26 acquires a corresponding report from the report storage unit 25 and periodically transmits the report to the customer, such as daily, weekly, monthly, or monthly. The Internet or other public line or private line can be used as a report transmission path.

  On the other hand, the report receiving unit 16 of the apparatus 10 receives the transmitted report. The report storage unit 17 stores the received report. The customer can browse the report stored in the report storage unit 17 using the report browsing unit 18. Further, the customer can directly browse the report addressed to himself / herself stored in the report storage unit 25 of the report creation system 20 using the report web browsing unit 19.

  Instead of transmitting the report by the report transmission unit 26, the report stored in the report storage unit 25 can be presented to the customer by e-mail or by carrying a recording medium. In this case, the report is directly stored in the report storage unit 17.

  The report created by the report creating unit 24 and presented to the customer indicates the degree of effective use of the device 10 that is each measurement / control / information device. Effective utilization can be shown as an evaluation compared to a benchmark. You can also show comparison data with other companies in the same industry, your own factories, or your own past. As a result, the customer can objectively and easily grasp to what extent the installed device fulfills the purpose of introduction.

  For example, customers who have introduced a distributed control system can grasp the current controllability and monitoring efficiency regarding the improvement of controllability and the improvement of monitoring efficiency, which are the objectives of system introduction, and how much controllability compared to before. And monitoring efficiency has been improved. In addition, it is possible to grasp how much controllability and monitoring efficiency are obtained as compared with other factories and other devices of the same company, or similar factories and devices of other companies in the same industry.

  In addition, based on such reports, it is possible to ask the equipment provider to provide consulting for improvement of equipment that has not been used effectively by customers, and after understanding the processes and operations. Consultation is available.

  On the other hand, from the perspective of the equipment provider, by presenting the report to the customer, the various measurement / control / information equipment delivered can be fully utilized, and the product can be evaluated correctly by the customer. , Can increase customer satisfaction.

  As described above, according to the operation status analysis method of the present invention, the device provider side analyzes the operation status of the device using information acquired from the device, so that the device is based on the analysis result. It is possible to easily grasp the degree of utilization.

  The scope of application of the present invention is not limited to the above embodiment. The present invention can be widely applied to an operation state analysis method and an operation state analysis device that analyze the operation state of the apparatus.

The figure which shows the concept of the driving | running condition analysis method of one Embodiment. The block diagram which shows the structure of an introduction apparatus and a report production system functionally. The block diagram which shows the example which provided a part of index value presentation function outside the apparatus.

2 Provider 10 Device 11 Information collection unit (Information acquisition means)
23 Index Value Analysis Unit (Analytical means)

Claims (14)

In the operating status analysis system that analyzes the operating status of the devices connected to the distributed field control system in the analysis unit,
Each of the devices
Information handled by the distributed control system, information collecting means for collecting information on the control state of the device by the distributed field control system or the operation of the device by the distributed field control system;
By calculation based on the information collected by the information collecting means, an index value is calculated as a value relating to the utilization degree of the apparatus and representing a period longer than the information collection interval in the information collecting means. Index value calculation means;
Index value storage means for storing the index value calculated by the index value calculation means;
Comprising
The analysis unit
Index value collection means for collecting the index values from the index value storage means of a plurality of the devices introduced into a plurality of the sites;
Normalizing means for normalizing the index values collected by the index value collecting means;
Comparative analysis means for performing a comparative analysis of the utilization of the apparatus between the plurality of sites based on the index value normalized by the normalization means;
An operating condition analysis system comprising: 2. The information according to claim 1, wherein the information includes a control value that is a control target in the distributed field control system, and the index value includes an integrated value of a deviation amount from a set value of the control value. Driving situation analysis system. The driving condition analysis system according to claim 1, wherein the index value includes a time ratio in which a control value that is a control target in the distributed field control system is automatically controlled. The information includes a control value that is a control target in the distributed field control system, and the index value includes a time ratio during which the control value is controlled within a predetermined range. The driving | running condition analysis system of any one of. The driving condition analysis system according to any one of claims 1 to 4, wherein the index value includes a frequency of a screen expansion operation in the distributed field control system. The driving condition analysis system according to any one of claims 1 to 5, wherein the index value is a frequency of manual operation in the distributed field control system. The analysis unit reports, as a comparison analysis result by the comparison analysis unit, a report indicating the utilization of the device on the comparison with the utilization of the devices constituting the other distributed field control system. The driving condition analysis system according to any one of claims 1 to 6, further comprising report transmission means for transmitting the report. 8. The driving analysis system according to claim 7, wherein the device includes receiving means for receiving the report transmitted by the report transmitting means. The driving condition analysis system according to claim 1, wherein the normalizing unit normalizes the index value using another index value. The operating condition analysis system according to any one of claims 1 to 9, wherein the normalizing means normalizes the index value based on a status of a plant related to the device. The driving condition analysis system according to claim 1, wherein the device is a control device that controls a field device. The operation state analysis system according to claim 1, wherein the device is a field device. The driving condition analysis system according to any one of claims 1 to 12, wherein the index value collecting unit collects the index value from the storage unit of a plurality of the apparatuses via a public line. . In an operation state analysis method for analyzing an operation state of a device connected to a distributed field control system in an analysis unit,
In each of the devices,
Collecting information on control status of the device by the distributed field control system or operation on the device by the distributed field control system, which is information handled by the distributed control system;
An index as a value representative of a degree of utilization of the apparatus and representing a period longer than the information collection interval in the step of collecting the information by calculation based on the information collected in the step of collecting the information Calculating a value;
Storing the index value calculated by the calculating step;
Run
In the analysis unit,
Collecting the index value stored by the storing step from each of the plurality of devices introduced to the plurality of sites;
Normalizing the index values collected by collecting the index values;
Performing a comparative analysis of the utilization of the apparatus between the plurality of sites based on the index value normalized by the normalizing step;
The driving | running condition analysis method characterized by performing.

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