JP2013109711A - Plant model creation device and plant operation support system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce a workload at the time of constructing an initial plant model.SOLUTION: Before operation of a plant, an arithmetic control unit 13 extracts necessary plant model units from a plant model unit library according to inputted equipment connection information of plant equipment, reflects equipment information of the plant equipment inputted next, in a model parameter of the extracted plant model unit and constructs an initial plant model. The arithmetic control unit inputs operation data obtained with the operation of the plant as an opportunity, into the initial plant model, calculates a model output value, determines deviation degree, and adjusts the model parameter. The adjustment of the model parameter and simulation are repeated until the model output value enters a preset permissible range of the deviation degree, to obtain a plant model.

Description

  The present invention relates to a plant model generation device and a plant operation support system that supports plant operation using a plant model created by the device.

  In plants such as chemicals, petroleum, electric power, gas, steel, chemicals, and water and sewage systems, physical quantities such as humidity, temperature, and pressure are calculated by simulation using a plant model to perform optimal operation of the plant. Here, the plant model is a model of various plant equipment that constitutes an actual plant, and includes, for example, heat exchangers, drums, pumps, valves, piping, etc., and these are modeled as independent equipment during plant construction. It is necessary to make it.

  The simulator using the plant model always receives operation data indicating the state of each plant device constituting the plant, and adjusts the plant parameters so that the output value of the plant model is adapted to the acquired operation data. By controlling in this way, the plant model and the plant can be followed in real time, and the behavior of the actual plant can be predicted by executing the simulation. Many techniques related to the adjustment of the plant parameters have been proposed, and as prior art documents, for example, the following publications are known.

Japanese Patent Laid-Open No. 07-160309 JP 09-179604 A JP 2001-154705 A Japanese Patent Laying-Open No. 2005-078545 JP 2005-332360 A

  Conventionally, plant training simulators and online plant simulators that support plant operations receive information for creating plant models from companies that own plants, construct plant models, and perform tuning using operation data, etc. Do. For this tuning, for example, the techniques disclosed in each of the above patent documents can be used. In other words, the plant model parameters are selected based on the operation data acquired from the plant, and simulation is performed. The parameters are changed until the output value of the plant model falls within the allowable range, so that the plant model always follows the state of the plant. . This makes it possible to accurately perform abnormality diagnosis and future prediction.

  Conventionally, the construction of a plant model is performed after receiving a request for introduction of an operation training simulator or an operation support tool from a company that owns the plant. In particular, in petrochemistry and general chemistry, a chemical plant model involving a chemical reaction requires a plant model for each reaction, and therefore it takes time to accumulate the plant model. On the other hand, a plant model is efficient if it is possible to refer to a model created in the past, if possible, or to use a commercially available plant model / unit library without building it from scratch.

  The present invention has been made based on the above-mentioned demands, and at the time of plant construction, a mechanism for extracting a necessary model from a plant model / unit library prepared in advance and automatically generating a prototype of the plant model is constructed. Operation using the plant model generated by making adjustments using the operation data collected from the plant from the start-up of the plant to the transition to the stable operation period. An object of the present invention is to provide a plant model generation apparatus and a plant operation support system capable of supporting operation of a plant by modifying the plant model so that a support tool can be used.

  In order to solve the above-described problem, a plant model generation apparatus according to a first aspect of the present invention creates a plant model obtained by modeling a plant component device, at least an input / output device, a storage device, and an arithmetic control device. The calculation control device includes a plant model / unit library stored in the storage device in accordance with device connection information of the plant equipment input via the input / output device. The necessary plant model units are extracted from the inside, the extracted plant model units are connected, and the equipment information of the plant equipment that is subsequently input is reflected in the model parameters of the extracted plant model units. The initial model building unit for generating the initial plant model and the operation of the plant The operation data obtained from the model is input to the initial plant model to calculate the model output value, the calculated model output value is compared with the operation data to determine the divergence, and the determined The model parameter of the initial plant model is adjusted based on the degree of divergence, and the simulation is performed using the adjusted model parameter, and the model parameter value is adjusted until the model output value falls within a preset tolerance of the degree of divergence. And a model updating unit that repeatedly executes the simulation.

  According to the plant model generation apparatus according to the first aspect of the present invention, the arithmetic and control unit is configured to store the plant model / unit library prepared in advance according to the equipment connection information of the plant equipment input by the initial model construction unit. Extract necessary plant model units from inside. Then, the extracted plant model units are connected, and the device information of the plant equipment that is subsequently input is reflected in the model parameters of the extracted plant model unit to generate an initial plant model. And a model update part inputs the operation data acquired from a plant into an initial plant model, calculates a model output value, compares the calculated model output value and operation data, and determines the divergence degree. Then, the model parameter of the initial plant model is adjusted based on the determined divergence degree, and the simulation is performed using the adjusted model parameter, and the model parameter is set until the model output value falls within a predetermined divergence degree allowable range. Repeat the adjustment and simulation. In this way, an initial plant model can be created by utilizing a plant model / unit library prepared in advance, and therefore the work load is greatly reduced compared to the case of building an initial plant model from scratch.

  In the blunt model creation device according to the first aspect of the present invention, the arithmetic control device stores the determined degree of divergence and an update record of model parameters in the plant model unit in the storage device, and the update record. And a model determination function for detecting that the initial plant model has converged from at least one of the variation range of the divergence degree and the number of times of updating the model parameter, and notifying the input / output device. Features. According to the present invention, the arithmetic and control unit analyzes the model update record by the model determination unit and detects that the initial plant model has converged from at least one of the variation range of the divergence degree and the number of model parameter updates. To inform the outside. For this reason, the operator or the vendor can make the operation of the plant shift to a stable state. In addition, the plant model can always follow the state of the actual plant by performing tuning using operation data collected from the plant even after shifting from the plant startup to the stable operation period.

  In order to solve the above-described problems, a plant operation support system according to a second aspect of the present invention includes a plant operation control device that controls operation of a plant, and a plant model in which the plant operation control device is connected via a network. A plant operation support system comprising a generation device and supplementing operation of the plant using a plant model created by the plant model generation device, wherein the plant model generation device is connected to an input device of a plant device. According to the information, the necessary plant model units are extracted from the prepared plant model / unit library, the extracted plant model units are connected, and the device information of the plant equipment that is subsequently input is extracted. , To the model parameters of the extracted plant model unit The initial model construction function for generating an initial plant model by reflecting the operation of the plant, the operation data acquired from the plant is input to the initial plant model, the model output value is calculated, and the calculated The model output value is compared with the operation data to determine the degree of divergence, the model parameter of the initial plant model is adjusted based on the determined degree of divergence, and the simulation is performed using the adjusted model parameter. A model update function for repeatedly adjusting the model parameters and repeatedly executing the simulation until the model output value falls within a preset allowable range of the divergence, the determined divergence, and the plant model unit Save the model parameter update record in, and save the saved update record A model determination function that detects that the initial plant model has converged from at least one of the variation range of the divergence degree and the number of updates of the model parameter, and informs the input / output device; The plant operation control device is created by the plant model generation device and operates the plant according to the converged plant model.

  According to the plant operation support system according to the second aspect of the present invention, a function for automatically generating a plant model suitable for a plant to be constructed using a plant model / unit library prepared in advance in a plant model generation device. By creating an initial plant model, it is possible to significantly reduce the work burden when building the initial plant model, and it is collected from the plant even after the plant has been started and moved to the stable operation period. By making adjustments using the operation data and correcting and tuning the plant model so that the operation support tool using the created plant model prototype can be used, the plant model can always follow the actual plant state. Plant operation support becomes possible. This makes it possible to accurately perform abnormality diagnosis and future prediction.

  According to the present invention, at the time of constructing a plant, an operation for constructing an initial plant model is performed by constructing a mechanism for automatically generating a prototype of a plant model by extracting a necessary model from a plant model / unit library prepared in advance. A plant model that reduces the burden and makes adjustments using the operation data collected from the plant until the transition from the plant startup to the stable operation period, and the operation support tool using the created plant model can be used It is possible to provide a plant model generation apparatus and a plant operation support system that can be modified to be capable of supporting plant operation.

It is a block diagram which shows the structure of the plant operation assistance system which concerns on embodiment of this invention. It is a flowchart which shows the operation | movement before plant operation of the plant model production | generation apparatus which concerns on embodiment of this invention. It is a flowchart which shows the operation | movement after plant operation of the plant model production | generation apparatus which concerns on embodiment of this invention.

  Hereinafter, an embodiment for carrying out the present invention (hereinafter simply referred to as the present embodiment) will be described in detail with reference to the accompanying drawings.

(Configuration of the embodiment)
A plant operation support system 1 shown in FIG. 1 has a configuration in which a plant model generation apparatus 10 is connected to a plant 20 via a network 30 such as an IP (Internet Protocol) line. Here, the plant 20 includes a plant operation control device that is a control computer for managing the operation of the plant, and the tuning of the initial plant model executed by the plant model generation device 10 and the tuning by updating is distributed. It is assumed to be realized by a control system (DCS; Distributed Control System). Processing related to the construction and update of the initial plant model will be described later with reference to the flowcharts shown in FIGS.

  The plant model generation device 10 includes an input / output device 11, a storage device 12, and an arithmetic control device 13 in terms of hardware.

  The input / output device 11 inputs the device connection information (P & ID), the device list, and the device information (TAG) list of each plant device constituting the plant 20 to the arithmetic control device 13, and performs processing by the arithmetic control device 13. For example, a keyboard display. The storage device 12 is composed of, for example, a large-capacity storage device such as a hard disk, in which a program executed by the arithmetic control device 13 is allocated and stored in a program storage area, and a process model / unit library is stored. In addition, a model update record is allocated and stored in the working storage area.

  In the plant model generation apparatus 10 according to the present embodiment, the process model / unit library prepared in advance for constructing the initial plant model is based on the dynamic simulator “Visual Modeler V2” provided by Omega Simulation Co., Ltd. Is a standard unit model offered as Here, at least one or more plant equipment such as valves, pumps, piping equipment, mixing / split flow, in / out of the system, tanks, heat exchangers, distillation towers, compressors / blowers, turbines, furnaces, reactors, etc. are models. Included as

  The arithmetic and control unit 13 functionally includes an initial model construction unit 131, a model update unit 132, and a model determination unit 133. Here, the blocks shown as the initial model construction unit 131, the model update unit 132, and the model determination unit 133 are functions to be described later when the arithmetic control device 13 sequentially reads and executes the program stored in the program area of the storage device 12. Is a functional block to be realized.

  The initial model construction unit 131 extracts a necessary plant model unit from the plant model / unit library stored in the storage device 12 in accordance with the P & ID input via the input / output device 11, and extracts the extracted plant model. The function of connecting the units and reflecting the input device list and TAG list in the model parameters of the extracted plant model unit to generate an initial plant model (plant model prototype) is executed.

  The model updating unit 132 inputs the operation data acquired from the plant 20 to the initial plant model and calculates the model output value when the plant 20 is operated, and compares the calculated model output value with the operation data. The degree of divergence is determined, and the model parameters of the initial plant model are adjusted based on the determined degree of divergence, and simulation is performed using the adjusted model parameters, and the model output value is allowed to be set in advance. It has a function of adjusting model parameters and repeatedly executing simulation until it falls within the range.

  The model determination unit 133 stores the divergence degree determined by the model update unit 132 and the update record of the model parameter in the plant model unit in the storage device 12 (model update record), analyzes the update record, and analyzes the divergence degree. It has a function of detecting that the initial plant model has converged from at least one of the fluctuation range and the number of model parameter updates, and notifying the input / output device 11.

  Although not shown in FIG. 1, a communication device that controls an interface with the network 30 is required between the network 30 and the plant model generation device 10. Here, a TCP / IP (Transmission Control Protocol) is required. Operation data is acquired from the plant 20 by a protocol according to / Internet Protocol.

(Operation of the embodiment)
Hereinafter, the operation of the plant model generation apparatus 10 shown in FIG. 1 will be described in detail with reference to the flowcharts shown in FIGS. 2 and 3.

  First, an initial plant model generation process before plant operation by the plant model generation device 10 will be described with reference to the flowchart of FIG. When the initial model construction unit 131 detects the input of the P & ID from the input / output device 11 (step S101 “YES”), the arithmetic control device 13 takes in the input information (step S102) and stores the process stored in the storage device 12. The model / unit library is referred to (step S103). Then, a process model unit corresponding to the selected process model unit is selected, and a process of connecting the selected process unit models is executed (step S104).

  Next, the initial model construction unit 131 takes in the device list and the TAG list that are subsequently input via the input / output device 11 (steps S105 “YES”, S106), and the size, material, and performance coefficient indicated in these lists. Is reflected in the model parameters of the selected process model unit, thereby constructing an initial plant model that is a prototype of the plant model (step S107) and storing it in the work area of the storage device 12 (step S108). ).

  Next, an initial plant model tuning process after plant operation will be described with reference to the flowchart of FIG. In the arithmetic and control unit 13, the model update unit 132 starts executing the simulation (step S201 “YES”) with the operation of the plant 20 (step S202). For this reason, operation data is acquired from the plant 20 by communication via the network 30 (step S203), given as an input of an initial plant model that has been previously constructed and stored in the storage device 12, and a model output value is calculated ( Step S204).

  In the simulation of step S202, the plant model generation apparatus 10 according to the present embodiment uses data reconciliation (DDR) with dynamic compensation to match the model to the operation data by the least square method even when the plant is in an unstable state. A simulation using a tracking simulator with added technology shall be executed. About this DDR technology, Yokogawa Technical Report VOL. 52, no. 1 (2008), pp35-pp37, “Renovation of Plant Operation by Tracking Simulator”.

  Next, the model update unit 132 compares the model output value and the operation data to determine the divergence degree (step S205), adjusts the model parameter in the process unit model selected based on the divergence degree, and The update record is stored in the storage device 12 (step S206). Subsequently, the model updating unit 132 compares the determined divergence degree with an allowable range in which a fluctuation range composed of upper and lower limits of the divergence degree is defined in advance (step S207). If the degree of divergence is not included in the allowable range, a part of the plant model is replaced by a statistical method (step S208), the storage process to the storage device 12 is executed (step S209), and the process of step S202 is performed. Return to and resume the simulation.

  That is, the model updating unit 133 performs simulation with the initial plant model using the adjusted model parameter, and repeatedly performs parameter adjustment and simulation until the model output value falls within a preset variation range of the divergence degree. (Step S207 “YES”). For example, if the model is a reactor, the reactor outlet temperature and the like are calculated, and this calculated value is compared with the measured value indicated by the obtained operation data. Adjust the thermal coefficient parameter so that the gap is minimized.

  At this time, the model determination unit 133 stores the divergence determined by the model update unit 132 and the update record of the model parameter in the process model unit in the storage device 12 each time, and analyzes this record. Then, it is detected that the initial plant model has converged (determined) from at least one of the variation range of the divergence degree and the number of model parameter updates. Here, if it is determined that it has converged (step S207 “YES”), the fact is notified to the input / output device 12 (step S210).

  That is, the model determination unit 133 sends a signal indicating that the model has been determined to the input / output device 11 when the plant 200 enters the stable operation state and the parameter update for model adjustment also converges. The DCS vendor takes out a plant model that has grown with the signature, and builds a model to be used in an online simulator based on this plant model. In other words, it is possible to reconstruct an optimum model by determining that a portion with a large degree of deviation cannot be handled by the standard unit model.

(Effect of embodiment)
As described above, according to the plant model generation apparatus 10 according to the present embodiment, an initial plant model can be created using a plant model / unit library prepared in advance. Compared to the construction of the initial plant model, the workload is greatly reduced. In addition, by analyzing the model update record and detecting that the initial plant model has converged from at least one of the fluctuation range of the divergence degree and the number of model parameter updates, the outside of the plant is in a stable state. In addition, the plant model can always follow the actual plant state by tuning using the operation data collected from the plant even after shifting from the plant startup to the stable operation period. be able to.

  That is, the plant model generation device 10 automatically generates and tunes the original model of the plant model that realizes plant operation support (optimum operation, avoidance operation, predictive operation, etc.) using an online simulator, thereby making it easy to construct an initial model. Can be omitted. In other words, the plant model failure points in the actual operational state at the time of operation are known, so the points to focus on in the model construction can be identified. For this reason, by using the prototype of the plant model, The effect of the operation support tool provided by the DCS vendor can be shown.

  The plant model generation device 10 according to the present embodiment is configured to notify the operator by notifying the input / output device 11 of the model confirmation, but is not limited to the display on the DCS screen, and directly communicates. May be notified to the DCS vendor. In the plant model generation apparatus 10 according to the present embodiment, this function is described as being implemented in the DCS. However, this function may be implemented on a computer that can communicate with the DCS.

  In addition, according to the plant operation support system 1 according to the present embodiment, the plant model generation apparatus 10 uses a plant model / unit library prepared in advance, and automatically generates a plant model suitable for a plant to be constructed. By creating an initial plant model, it is possible to greatly reduce the work burden when building the initial plant model, and it is collected from the plant even after shifting from the plant startup to the stable operation period. By making adjustments with the operation data and modifying the plant model so that the operation support tool using the prototype of the created plant model can be used, the plant model can always follow the state of the actual plant. Driving support becomes possible. This makes it possible to accurately perform abnormality diagnosis and future prediction. Moreover, although the exact model based on physics and a chemical law was shown as a plant model, the statistical model constructed | assembled from the relationship between an input and an output may be used.

  As mentioned above, although preferred embodiment of this invention was explained in full detail, it cannot be overemphasized that the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above-described embodiments. Further, it is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

  DESCRIPTION OF SYMBOLS 1 ... Plant operation assistance system, 10 ... Plant model production | generation apparatus, 11 ... Input / output device, 12 ... Memory | storage device, 13 ... Arithmetic control device, 20 ... Plant, 30 ... Network 131... Initial model construction unit 132... Model update unit 133 133 Model determination unit

Claims (3)

A plant model generation device comprising at least an input / output device, a storage device, and an arithmetic and control device for creating a plant model obtained by modeling a plant component device,
The arithmetic and control unit is
In accordance with the equipment connection information of the plant equipment input via the input / output device, a necessary plant model unit is extracted from the plant model / unit library stored in the storage device, and the extracted plant model unit is extracted. An initial model construction unit for generating an initial plant model by reflecting the equipment information of the plant equipment that is subsequently input to the model parameters of the extracted plant model unit;
Triggered by the operation of the plant, the operation data acquired from the plant is input to the initial plant model to calculate a model output value, and the calculated model output value is compared with the operation data to determine the difference between them. And determining the degree of divergence, adjusting the model parameter of the initial plant model based on the determined degree of divergence, performing a simulation using the adjusted model parameter, and the model output value of a predetermined degree of divergence Adjustment of the model parameters until entering an allowable range, and a model update unit that repeatedly executes the simulation;
A plant model generation device characterized by comprising: The arithmetic and control unit is
The determined degree of divergence and an update record of the model parameter in the plant model unit are stored in the storage device, and the update record is analyzed to analyze at least one of the variation range of the divergence degree and the number of updates of the model parameter. The plant Dell generating apparatus according to claim 1, further comprising a model determination function for detecting that the initial plant model has converged and notifying the input / output device. The plant operation control device that controls the operation of the plant, and the plant operation control device includes a plant model generation device connected via a network, and the plant model is generated using the plant model generated by the plant model generation device. A plant operation support system that performs operation support supplementation,
The plant model generation device is
In accordance with the equipment connection information of the plant equipment that is input, the necessary plant model units are extracted from the plant model / unit library prepared in advance, the extracted plant model units are connected, and then input. An initial model construction function for generating the initial plant model by reflecting the equipment information of the plant equipment in the model parameters of the extracted plant model unit;
Triggered by the operation of the plant, the operation data acquired from the plant is input to the initial plant model to calculate a model output value, and the calculated model output value is compared with the operation data to determine the difference between them. And determining the degree of divergence, adjusting the model parameter of the initial plant model based on the determined degree of divergence, performing a simulation using the adjusted model parameter, and the model output value of a predetermined degree of divergence A model update function for repeatedly adjusting the model parameters and repeatedly executing the simulation until entering an allowable range;
The determined degree of divergence and the update record of the model parameter in the plant model unit are stored, and the stored update record is analyzed to detect at least one of the fluctuation range of the divergence degree and the number of times of update of the model parameter. A model determination function for detecting that the initial plant model has converged and notifying the input / output device;
Have
The plant operation control device is
Created by the plant model generation device, and operates the plant according to the converged plant model,
A plant operation support system characterized by that.

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